Hercules SHIMANO SC-E800 Manual Download

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MY22H03 - 32_1.0_04.10.2021

192

Troubleshooting, fault clearance and repair

9.3

Rechargeable battery

Symptom

Cause

Remedy

The battery discharges

quickly.

The battery may be at the end of its

service life.



Replace battery with new one.

All five battery indicators are

continuously lit.

The drive unit firmware version may not be

up to date.



Contact your specialist dealer.

The battery cannot be

recharged.

Is the charger mains plug firmly connected

to the socket?

Disconnect charger mains plug. Insert the mains plug
again.

Repeat charging process.

Contact your specialist dealer if there is still no
assistance.

Is the charger plug firmly

inserted into the battery?

Disconnect charger’s charger plug. Insert charger plug
again.

Repeat charging process.

Contact your specialist dealer if there is still no
assistance.

Is the adapter firmly connected to the

charger plug or the battery's charging

port?

Connect the adapter firmly to the charger plug or the
battery charging port.

Start charging.

If the battery still won’t charge, contact your specialist
dealer.

Is the battery, the connection terminal for

the battery charger, charger adapter or

battery dirty?

Wipe with dry cloth to clean the connection terminals.

Start charging.

If the battery still won’t charge, contact your specialist
dealer.

The battery does not start

charging when the charger

is connected.

The battery may be at the end of its

service life.



Replace battery with new one.

The battery and charger

become hot.

The temperature of the battery or the

charger may have exceeded the operating

temperature range.

Interrupt charging process.

Wait a moment.

Start charging.

If the battery becomes too hot to touch, there might be a
problem with the battery. Contact your specialist dealer.

The charger is hot.

If the charger is used continuously to

charge batteries, it may become hot.



Wait a moment before using the charger again.

The LED on the charger

does not light up.

Is the charger plug firmly connected to

battery?

Check the charging port for any contaminants.

Insert charger plug.

Contact your specialist dealer if the LEDs on the charger
still don't light up.

Is the battery fully charged?

The LED on the battery charger will go out when the
battery is fully charged. This is not a malfunction.

Disconnect charger mains plug.

Insert mains plug into the charger again.

Wait a moment.

Start charging.

Contact your specialist dealer if the LEDs on the charger
still don't light up.

The battery cannot be

removed.



Contact your specialist dealer.

Table 57:Error solution for battery

Summary of Contents for SHIMANO SC-E800

Page 1: ...f original operating instructions for HERCULES pedelecs with SHIMANO SC E800 on board computer NOS FS 2 1 22 R 0001 MY22H03 32_1 0_04 10 2021 IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE ...

Page 2: ...ncorrect tightening torque 14 2 1 3 3 Incorrect component 14 2 1 4 Risk of amputation 14 2 1 5 Key breaking off 14 2 1 6 Malfunctions due to Bluetooth 15 2 2 Toxic substances 16 2 2 1 Brake fluid 16 2 2 2 Suspension oil 16 2 2 3 Lubrication oil 16 2 2 4 Defective battery 16 2 3 Requirements for riders 16 2 4 Vulnerable groups 16 2 5 Personal protective equipment 16 2 6 Safety guards 16 2 7 Safety ...

Page 3: ...hain drive layout 41 3 3 7 2 Belt drive layout 41 3 3 8 Electric drive system 42 3 3 8 1 Motor 42 3 3 8 2 Battery 42 3 3 8 3 Rechargeable battery 43 3 3 9 Riding light 43 3 3 10 Charger 43 3 3 10 1 On board computer 44 3 3 10 2 Control panel 44 3 4 Description of controls and screens 45 3 4 1 Handlebars 45 3 4 2 On board computer 46 3 4 2 1 Main screen 46 3 4 3 Warnings and errors 48 3 4 3 1 Warni...

Page 4: ...t backlash 65 5 4 Pedelec sale 65 6 Operation 6 1 Risks and hazards 66 6 2 Tips for a greater range 68 6 3 Error messages 69 6 3 1 Battery error message 69 6 3 2 On board computer warnings 70 6 4 Error message screen 71 6 5 Instruction and customer service 72 6 6 Adjusting the pedelec 72 6 6 1 Preparing 72 6 6 2 Pedelec adjustment procedure 73 6 6 3 Determining the sitting position 74 6 6 4 Adjust...

Page 5: ...6 6 6 17 1 Adjusting the lights 106 6 6 18 Adjust on board computer 108 6 6 19 Opening the settings menu 109 6 6 20 Closing the settings menu 110 6 6 20 1 Sets the language 110 6 6 20 2 Setting units 110 6 6 20 3 Changing the displayed speed 110 6 6 20 4 Adjusting the clock 111 6 6 20 5 Changing the brightness 111 6 6 20 6 Changing the beep sound 111 6 6 20 7 Automatic light setting 112 6 6 20 8 A...

Page 6: ...ance 127 6 21 4 Switching the journey information 127 6 22 Brake 128 6 22 1 Using the brake lever 128 6 23 Suspension and damping 129 6 23 0 1 Adjusting the RockShox compression adjuster 130 6 24 Gear shift 131 6 24 1 Using the derailleur gears 131 6 25 Parking 132 6 25 1 Screwing in the All Up handlebars 132 7 Cleaning servicing and maintenance 7 1 Before each ride 138 7 1 1 Checking the guards 1...

Page 7: ...guard 146 7 4 5 Servicing the kickstand 146 7 4 6 Stem 146 7 4 7 Handlebars 146 7 4 8 Handle 146 7 4 8 1 Rubber handles 146 7 4 8 2 Leather handle 146 7 4 9 Seat post 147 7 4 9 1 Suspension seat post 147 7 4 9 2 Carbon seat post 147 7 4 10 Rim 147 7 4 11 Leather saddle 147 7 4 12 Hub 147 7 4 13 Spoke nipples 147 7 4 14 Gear shift 148 7 4 14 1 Rear derailleur articulated shafts and jockey wheels 14...

Page 8: ...60 8 Maintenance 8 1 Initial inspection 161 8 2 Maintenance 161 8 3 Component specific maintenance tasks 161 8 4 Carry out initial inspection 164 8 5 Maintenance instructions 165 8 5 1 Servicing the frame 172 8 5 1 1 Servicing the carbon frame 172 8 5 2 Checking the pannier rack 172 8 5 3 Servicing axle with quick release 172 8 5 4 Maintaining the stem 173 8 5 5 Servicing the gear hub 173 8 5 5 1 ...

Page 9: ... soft on inclines 201 9 5 2 4 Excessively hard damping on bumps 202 9 6 Repair 203 9 6 1 Original parts and lubricants 203 9 6 2 Replacing the lighting 203 9 6 3 Setting the front light 203 9 6 4 Checking tyre clearance 203 10 Recycling and disposal 10 1 Removal of waste guidelines 204 11 Documents 11 1 Assembly report 206 11 2 Maintenance log 208 11 2 1 Nos FS 2 1 212 12 Glossary 12 1 Abbreviatio...

Page 10: ...production 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 the approved te...

Page 11: ... 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 serious or even fatal injuries i...

Page 12: ...te the pedelec with the owner The frame number is the most important identifier for verifying ownership 1 7 Identifying the operating instructions The operating instructions identification number is located in bottom left hand corner of each page The identification number is composed of the document number the version number and the release date Type no Model Pedelec type 22 R 0001 NOS FS 2 1 Moun...

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

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

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

Page 16: ...cal devices such as pacemakers and hearing aids Likewise harm to people and animals in the immediate vicinity cannot be completely excluded Never use the pedelec with Bluetooth when in close proximity to medical devices filling stations chemical plants areas at risk of explosion and in blasting zones Never use pedelec with Bluetooth in aircraft Avoid operating for longer periods in close proximity...

Page 17: ...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 18: ...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 19: ...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 20: ...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 21: ...itions stunt riding or acrobatics City and trekking bicycles Child s bicycles bicycles for young adults Mountain bikes Racing bicycle Cargo bike Folding bicycle City and trekking bicy cles are not sports bicycles If used for sports the rider can expect reduced riding stability and dimin ished comfort Cycles for children and young adults are not toys Mountain bikes must be retrofitted with lighting...

Page 22: ... total weight PTW The pedelec may only be loaded to its maximum permitted total weight PTW The maximum permitted total weight is the weight of the fully assembled pedelec plus body weight plus baggage Type no Model PTW kg 22 R 0001 Nos FS 2 1 125 Table 8 Type number model and PTW ...

Page 23: ...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 24: ...ever drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps over 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 6...

Page 25: ... 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 markings warn of hazards Se...

Page 26: ...hub 3 Fork 4 Steering headset 5 Handlebars 6 Stem 7 Frame 8 Rear frame damper 9 Seat post 10 Saddle 11 Reflector 12 Rear wheel 13 Gear shift and rear wheel hub 14 Rear wheel brake 15 Chain 16 Frame number 17 Motor under motor cover 18 Pedal 19 Battery and type number 20 Front wheel brake 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

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

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

Page 29: ...ork returns to its original position If there is a damper it decelerates movement preventing the suspension system from springing back in an uncontrolled manner and stopping the fork from vibrating up and down Dampers which dampen compressive deflection movements i e a compression load are called compression dampers or compression dashpots Dampers which dampen rebound deflection movements i e a re...

Page 30: ... the terrain green line when riding over bumps The suspension motion is predictable and controlled Figure 9 Optimum fork ride performance When optimally adjusted the fork counteracts deflection stays higher in its deflection range and helps the rider to maintain speed while riding on hilly parts of terrain Figure 10 Optimum fork ride performance on hilly terrain When optimally adjusted the fork de...

Page 31: ...ollow terrain green line when riding over bumps The suspension motion is predictable and controlled Figure 12 Optimum fork riding performance Suspension fork compression adjustment Only applies to pedelecs with this equipment The compression adjuster allows the rider to make quick adjustments to the fork s suspension behaviour to adapt to the changes in terrain It is intended for adjustments made ...

Page 32: ...wn 4 Dust seal 5 Q Loc 6 Axle 7 Fork end 8 Stanchion 9 Compression damper Air suspension fork structure Depending on the model the air suspension fork has either an air suspension assembly group orange and or a compression damper assembly blue and or a rebound damper assembly group red Figure 15 Internal structure of air suspension fork 1 Air valve 2 Air valve cap 3 Fork steerer 4 Sag setting whee...

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

Page 34: ...usted the rear frame damper deflects quickly and unhindered when the bike hits bumps and absorbs a bump Traction is retained blue line The saddle rises slightly when absorbing a bump green line Figure 18 Optimum rear frame damper ride performance over bumps ...

Page 35: ...ntrolled The rider is not thrown upwards or forwards green line The rebound adjuster setting depends on the air pressure setting A higher sag requires lower rebound damping Figure 19 Optimum rear frame damper riding performance Rear frame damper compression adjuster Only applies to pedelecs with this equipment The compression adjuster controls the compression lifting speed or the rate at which the...

Page 36: ... 3 3 3 3 RockShox rear frame damper The rear frame damper features air suspension a compression damper and a rebound damper Figure 21 Monarch RL as an example 1 Threshold lever 2 Rebound damper adjuster 3 Air valve 4 O ring 5 Scale 1 2 3 4 5 ...

Page 37: ...nsmit the driving braking and steering forces The tread can also help improve control on dirty road surfaces If a tyre with a deep tread is used on asphalt this may make an unpleasant noise when the brakes are used In such a case the specialist dealer needs to replace the tyre with a new one with a shallow tread Figure 23 Example Information on tyres Tyre pressure The permitted pressure range is i...

Page 38: ...alve Figure 26 Schrader valve 3 3 4 4 Spoke A spoke is a rod that connects the hub to the rim The bent end of the spoke which is hooked into the hub is called the spoke head A thread between 10 mm and 15 mm is attached to the other end of the spoke 3 3 4 5 Spoke nipples Spoke nipples are screw elements with an internal thread which fits onto the spoke thread Fitted spokes are tensioned by tighteni...

Page 39: ...rgency The brake is applied using the brake lever either with the brake lever and shift cable mechanical brake or with the brake lever and hydraulic brake cable hydraulic brake 3 3 5 1 Mechanical brake The brake lever is connected with the brake via a wire inside the shift cable also known as a Bowden cable Figure 27 Bowden cable structure 3 3 5 2 Hydraulic brake The brake fluid is in a closed hos...

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

Page 41: ...s to ensure sufficient tension when tightening the screw Patent saddle posts are fastened into the seat tube with either a quick release or a screwable clamp Figure 31 Example of a quick release 3 3 6 2 Suspension seat post Spring loaded seat posts can reduce shock after one time hard impacts thus improving ride comfort significantly However suspension seat posts are not able to compensate for bum...

Page 42: ...ction of travel 2 Chain or belt 3 Rear chain wheel or belt pulley 4 Front chain wheel or belt pulley 5 Pedal The pedelec is equipped with either a chain or belt drive 3 3 7 1 Chain drive layout Figure 33 Chain drive with derailleur gears 1 Rear derailleur 2 Chain A chain drive is compatible with Back pedal brake Hub gear or Derailleur gears 3 3 7 2 Belt drive layout Figure 34 Belt drive 1 Front be...

Page 43: ...uired for pedalling passes a certain level the motor is activated gently and assists the pedalling motion The motor force is determined by the set level of assistance The pedelec does not have a separate emergency stop or emergency shut off button The motor switches off automatically as soon as the rider stops pedalling the temperature is out side the permitted range there is an overload or the sh...

Page 44: ... off Assistance switches to ECO earlier if a battery powered light is connected 2 Gear shift 3 Light The battery s service life can be extended if the battery is well maintained and stored at the correct temperature The charging capacity will decrease with age even if the battery is maintained properly If the operating time is severely shortened after charging this is a sign that battery has reach...

Page 45: ...tem is operated using the on board computer II and the left hand control panel I The right hand control panel III switches the gears Figure 38 Overview of control panel position Depending on the model there can be three different control panels 3 switch control panel 2 switch control panel MTB control panel 3 switch control panel Figure 39 3 switch control panel 2 switch control panel Figure 40 2 ...

Page 46: ...ols and screens 3 4 1 Handlebars Figure 42 Detailed view of handlebars with SHIMANO SC E800 on board computer used as example 1 Rear wheel hand brake 2 Front wheel hand brake 3 Handle 4 Control panel 5 Air valve 6 Lock out 7 On board computer 8 Shifter 1 2 3 4 5 67 8 ...

Page 47: ...r 8 Assistance indicator System message 1 Shift mode indicator The rider has the choice between an automatic and manual gear shift The selected gear shift type is shown on the display screen 2 Gear level indicator The indicator is only visible if an electronic gear shift is used It shows the currently selected gear 3 Bluetooth indicator Displayed when an external device is connected via Bluetooth ...

Page 48: ...elec The higher the selected level of assistance the more the drive system assists with pedalling The following levels of assistance are available 8 Assistance indicator Shows the level of assistance The display colors change depending on the current assistance mode Display Function 100 81 80 61 60 41 40 21 20 1 0 Table 14 Charge level of the battery Display Function DST Distance travelled since t...

Page 49: ...shes between two system messages warnings and error messages 3 4 3 1 Warnings Warnings are displayed between the selected gear and the current speed on the system message screen There are limitations to the system s operation depending on the error type There is a table of system messages and remedial measures in Section 6 3 1 3 4 3 2 Error messages Error messages are shown on the entire display T...

Page 50: ...nel 1 Switch X 2 Switch A 3 Switch Y 2 switch control panel Figure 46 2 switch control panel 1 Switch X 2 Switch Y MTB control panel Figure 47 MTB control panel 1 Switch Y 2 Switch X 3 4 4 1 Control panel functions on right If there is no switch A on the switch control panel the button on the on board computer will control these functions SHIMANO shifter SL M5100 Figure 48 Shifter SL M5100 1 Shift...

Page 51: ...MY22H03 32_1 0_04 10 2021 50 Operation SHIMANO shifter SL M8100 Figure 49 Shifter SL M8100 1 Shifter 1 2 ...

Page 52: ...brake There is a hand brake on the left and right of the handlebars Figure 50 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 53: ... below 4 all the LEDs on the battery level indicator will go out However the battery level is still shown on the display screen System errors and warnings are displayed by various light patterns on the battery level indicator There is a table with all system messages in Section 6 2 System messages LED 1 2 3 4 5 Battery level 100 80 79 60 59 40 39 20 19 5 4 0 Figure 51 Battery level indicator when ...

Page 54: ...P800 motor Operating temperature 5 40 C Storage temperature 10 40 C Charging temperature 0 40 C Protection class with USB cover closed IPx7 A Weight about 0 06 kg USB port Max charging current for USB port 1000 mA B USB port charge voltage 5 V USB charging cable 1 270 016 360 C Bluetooth low energy Frequency 2402 2480 MHz Transmitting capacity 10 mW Maximum high frequency output 4 dBm Firmware ver...

Page 55: ...0 2021 54 Description 3 5 6 FIT Fast Charger 36 6 230 Nominal voltage Frequency Battery charge voltage Charging current max Protection class IP40 Operating temperature 5 C 40 C Storage temperature 10 C 50 C Weight 0 3 kg ...

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 21 Tightening torques and bits ...

Page 58: ...ight and dimensions during transportation Vehicle 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 21 19 1003 41 25 44 25 47 25 50 25 Table 22 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: ...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 64: ... 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 65: ...e 56 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 57 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 58 R pedal ...

Page 66: ... 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 5 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 67: ...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 68: ... 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 69: ...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 70: ... Contact your specialist dealer if the problem persists Error during security authentication This is displayed if no original drive unit is connected This is displayed if one of the cables is not connected 1 Connect original rechargeable battery and original drive unit 2 Check state of cables 3 Contact your specialist dealer if the problem persists Charge error This is displayed if an error occurs...

Page 71: ...en cycling Contact your specialist dealer W105 Unexpected power cut out detected The motor assistance functions are not restricted during display 1 Re start the system 2 If the problem persists contact your specialist dealer W200 W020 The power was switched off because the temperature exceeded the guaranteed operating range System functions do not start 1 If the battery overheats store in a cool p...

Page 72: ...persists E023 An electrical fault was detected inside the battery Drive system does not start 1 Press the On Off button battery 2 Contact your specialist dealer if the problem persists E024 The battery overcurrent protection was triggered Communication error in the drive system Drive system does not start Contact your specialist dealer E025 The battery does not detect the drive unit No original dr...

Page 73: ...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 6 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 74: ... 4 6 6 4 5 2 Handlebars 6 6 5 3 Stem 6 6 6 4 Handles 6 6 7 x 5 Tyres 6 6 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 optional Retract brake linings 6 6 9 1 6 6 9 2 6 6 9 3 6 5 9 8 6 6 9 5 7 Gear shift 6 6 10 8 Adjust suspension adjust suspension fork sag Adjust damper sag 6 6 12 6 6 13 x x Adjust the suspension fork rebou...

Page 75: ...higher than the handlebars Angle between upper arm upper body red line An angle of 90 is optimum The muscular support required in the arms back and shoulder girdle is reduced at 90 Above 90 Shoulders arms and hands need to provide a great deal of support the supporting muscles in the back are heavily strained and the load on the bearing surface shifts to the front Saddle handlebar height differenc...

Page 76: ...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 77: ...ower 3 Release the remote control operating lever when you have reached the desired height Figure 67 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 78: ... Figure 68 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 6 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 79: ...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 6 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 80: ...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 81: ... Adjusting the quill stem height 1 Undo screw 2 Pull quill stem out 3 Tighten screw 6 6 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 75 Raising the Ahead stem by fitting spacer rings The handlebar height is adjusted once during production using spacer ring...

Page 82: ...ustable stems are available in different lengths for quill and Ahead stems Figure 76 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 77 City bike blue and trekking bike position red by changing the angle a a b b c c ...

Page 83: ...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 78 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 6 7 1 Checking handlebar stability See Section 7 5 5 1 2 9 _ ...

Page 84: ... low tyre pressure often leads to premature wear in the tyre Cracking in the side wall is a typical consequence of very low tyre pressure Abrasion is also unnecessarily high On the other hand a tyre can absorb road impacts more effectively at a low pressure As a general rule wide tyres are operated at a lower tyre pressure They provide the option of exploiting the advantages of the lower tyre pres...

Page 85: ...ndlebar 2 Extend the index finger about 15 Figure 81 Brake handle position 3 Push brake lever outwards until the third finger phalanx sits in the brake lever recessed grip 6 6 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 86: ...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 84 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 87: ...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 88: ...king force increases over time The braking force is increased during break in time This is also the case when the brake pads or brake discs are replaced 1 Accelerate pedelec to 25 km h 2 Brake pedelec until it comes to a halt 3 Repeat process 30 to 50 times The disc brake is retracted and provides optimal braking power ...

Page 89: ...ger 3 Tighten attachment screw 6 6 10 1 SHIMANO shifter Only applies to vehicles with this equipment Figure 85 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 90: ... 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 91: ...O ring downwards until it reaches the top of the dust wiper seal Figure 86 Moving the O ring on the suspension fork 5 Get off the pedelec without allowing it to deflect 6 Note distance between dust wiper and the O ring This distance is the sag Figure 87 Sag 1 7 Check the sag 8 If the desired sag is not achieved the spring preload must be adjusted internally and or the coil spring replaced Contact ...

Page 92: ...ied for the fork model in question Remove spacers to reduce preload and increase the sag Fit spacers to increase preload and decrease sag You will find instructions on adjusting the preload internally in the RockShox maintenance instructions 10 Check the sag The spring preload setting can be used to finely adjust the sag However the preload does not change spring stiffness and is not suitable to s...

Page 93: ...rmal riding position 4 Ask your helper to push the O ring downwards until it reaches the top of the dust wiper seal Figure 91 Moving the O ring on the suspension fork 5 Get off the pedelec without allowing it to deflect 6 Note distance between dust wiper and the O ring This distance is the sag Figure 92 Sag 1 7 If the desired sag is not achieved the preload adjustment ring must be unscrewed bit by...

Page 94: ...4 Note distance between dust wiper and the O ring This distance is the sag Figure 95 Sag 1 5 Check the sag Figure 96 Mandatory sag range green and prohibited sag range red 6 If the desired sag is not achieved the spring preload must be adjusted internally and or the coil spring replaced Contact specialist dealer 1 Setting Sag Prohibited 30 High sensitivity 20 30 Low sensitivity 10 20 Prohibited 10...

Page 95: ...e preload spacer is positioned as standard 1 Figure 97 Screwing and unscrewing the preload adjustment ring Remove the preload spacer to reduce the preload and increase the sag 2 Move the preload spacer to the 10 mm preload position to increase preload and reduce the sag 3 Figure 98 Screwing and unscrewing the preload adjustment ring 8 Check the sag 1 2 3 ...

Page 96: ...mp on the valve 4 Pump the suspension fork to the required pressure Observe the levels in the air pressure table 5 The recommendations for air pressure in the front wheel suspension are also indicated on the rear of the fork and can be found at https trailhead rockshox com en 6 Remove the high pressure pump 7 Put on normal cycling clothing including baggage 8 Ask someone to hold the pedelec Stand ...

Page 97: ...he recom mended sag is between 10 and 20 hard or 20 to 30 soft Figure 102 Mandatory sag range green and prohibited sag range red 11 Increase or reduce the air pressure until you have reached the desired sag If the sag is correct tighten the air valve cap on the valve in a clockwise direction 12 If you are unable to achieve the desired sag internal settings may need to be made Contact your speciali...

Page 98: ...nd is used on pedelecs with a longer deflection Decreased sag 10 20 A decreased sag reduces sensitivity to bumps thus producing less suspension motion A lower sensitivity to bumps ensures a firmer more efficient ride performance and is generally used on pedelecs with a shorter deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surf...

Page 99: ...e corresponding to the total weight of the person riding including clothing and baggage 6 Deflect rear frame damper to compensate the air pressure 7 Put on normal cycling clothing including baggage 8 Ask someone to hold the bicycle Stand on the pedals 9 Deflect rear frame damper fully gently two or three times 10 Ask your helper to push the O ring against the wiper seal Figure 104 Moving the O rin...

Page 100: ...e The optimum sag percentage is 25 The sag level may be adjusted by 5 depending on the rider s preferences 20 to 30 12 The air pressure must be adjusted if the sag level is not reached Increase the air pressure to reduce the sag Decrease the air pressure to increase the sag ...

Page 101: ...o body weight spring stiffness deflection the terrain and the rider s preferences If the air pressure or spring stiffness increases the extension and rebound speeds also increase Rebound damping needs to be increased to achieve an optimal setting if the air pressure or spring stiffness are increased The damper rebounds at a controlled speed if the fork is optimally adjusted The wheel stays in cont...

Page 102: ...ecs with this equipment Figure 106 Adjusting the RockShox rebound The fork sag is adjusted Turn the rebound screw clockwise damper towards the tortoise symbol The rebound speed is decreased slower return Turn the rebound screw anti clockwise towards the hare symbol The rebound speed is increased faster return ...

Page 103: ...nd controlled The rider is not thrown upwards or forwards green line The rebound adjuster setting depends on the air pressure setting A higher sag requires lower rebound damping Figure 107 Optimum rear frame damper riding performance The suspension rebound speed affects the wheel s contact with the ground which in turn has an influence on control and efficiency The damper should rebound fast enoug...

Page 104: ...plies to pedelecs with this equipment Figure 108 Position and shape of the rebound adjuster red depends on the model The sag in the rear frame damper is adjusted Turn rebound adjuster clockwise The rebound damping is increased Turn rebound adjuster anti clockwise The rebound damping is reduced 2 5 ...

Page 105: ...ard on bumpy terrain Figure 109 Optimum rear frame damper ride performance over bumps Threshold The damping threshold prevents deflection until a medium impact or downward force occurs Threshold mode increases drive efficiency over level terrain The threshold setting can be used to improve pedalling efficiency over flat hilly level or slightly rugged terrain In threshold mode higher pedelec speeds...

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

Page 107: ...sk Example 3 If the front light is positioned too low the space ahead is not illuminated to an optimum extent and the rider s vision is reduced in the dark Figure 111 Light positioned too high 1 correctly 2 and too low 3 6 6 17 1 Adjusting the lights 1 Position the pedelec so that its front is facing a wall 2 Mark the height of the front light 1 on the wall with chalk 3 Mark half the height of the...

Page 108: ...high 1 correctly 2 and too low 3 7 Check the position of the light beam I if the upper edge of the light beam is above the front light height mark 1 the light will dazzle The front light must be positioned lower II If the mid point of the light beam is on or slightly below the mark showing half the front light 2 the light is optimally positioned III It the light beam is in front of the wall move f...

Page 109: ... Y 2 switch control panel Figure 116 2 switch control panel 1 Switch X 2 Switch Y Crash caused by distraction A lack of concentration 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...

Page 110: ... can only change the settings when you stop The main display screen appears 1 Press the button display or switch A The settings menu is displayed Figure 119 Opening the settings menu Switch Function WHEN RIDING BUTTON Switch journey data displayed WHEN SETTING Change display or confirm setting change 1 2 1 2 Switch Function WHEN RIDING X Change up Y Change down A Switch between automatic and manua...

Page 111: ... 20 3 Changing the displayed speed If there is a difference between the speed displayed on this product and the speed displayed on another device the displayed value can be changed This adjustment does not affect the motor s maximum speed of 25 km h The settings menu is opened 1 Press switch X or switch Y until DISPLAY SPEED is highlighted 2 Press the button display or switch A The speed settings ...

Page 112: ...switch A The clock has been set The settings menu is displayed 6 6 20 5 Changing the brightness The settings menu is opened 1 Press switch X or switch Y until BRIGHTNESS is highlighted 2 Press the button display or switch A The brightness settings menu appears Figure 122 Brightness settings menu Press switch X or switch Y until the desired brightness is highlighted 3 Press the button display or sw...

Page 113: ...ommended registered settings that can be changed as desired The settings can be adjusted to individual requirements Depending on the setting the battery consumption may increase and the supported travel range may be considerably reduced Details of the settings can be read in E TUBE PROJECT For details see the service instructions in E TUBE PROJECT The settings menu is opened 1 Press switch X or sw...

Page 114: ...is exposed to a severe impact due to a fall for example The connection between the motor and the link is interrupted instantly rendering the rear derailleur inoperable If you open RD PROTECTION RESET the connection between the motor and link is re established and the rear derailleur function reset The settings menu is opened 1 Press switch X or switch Y until RD PROTECTION RESET is highlighted 2 P...

Page 115: ...ch A until the displayed distance travelled starts flashing 3 Press the button display or switch A within the next 5 seconds DST distance travelled TIME trip time AVG average speed and MAX maximum speed are reset to zero If no button or switch is pressed within 5 seconds the main display screen appears 6 6 21 Connecting an external device 6 6 21 1 Connecting device via the ANT 1 Switch on the driv...

Page 116: ...Switch on the drive system 3 Establish connection The connection is established 6 8 Using E TUBE PROJECT E TUBE PROJECT is required to change drive system settings and update firmware The functions that can be configured differ depending on the pedelec You will find details in the E TUBE PROJECT operating instructions Functions allocated to each operating switch can be changed The pedelec s settin...

Page 117: ...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 48 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 118: ...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 119: ...reasons 6 9 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 9 6 Pannier rack The specialist dealer will advise on choosing a suitable pannier rack The s...

Page 120: ...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 11 Before each ride Check pedelec before each ride see section 7 1 Be alert to any unusual noises vibrations or odours while riding Be aler...

Page 121: ...teer and brake This can lead to a loss of control This may cause a crash with injuries You should practice how to use a loaded pannier rack safely before using the pedelec in public spaces Crushing the fingers in the spring flap The spring flap on the pannier rack operates with a high clamping force There is a risk of crushing the fingers Never allow the spring flap to snap shut in an uncontrolled...

Page 122: ... from material beneath and mould can form If the leather handles get wet dry handles completely 6 16 Using the pedals The ball of the foot is placed on the pedal when riding and pedalling Figure 132 Correct 1 and incorrect 2 foot position on the pedal 6 17 Using the multifunctional handlebars or bar ends Vary handle position to avoid overstraining and tiring the hands 6 17 1 Using leather handles ...

Page 123: ... 3 Remove the battery from the frame 4 Remove the battery key from the battery lock 6 19 0 2 Inserting the battery Figure 134 Inserting the battery 1 Place the battery into the 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 to ensu...

Page 124: ...ng process starts automatically The Charge Level battery indicator shows the battery level during charging When the drive system is switched on the display screen shows the charging process 4 The charging process is complete when the LEDs on the battery level indicator turn green 5 Disconnect the battery from the charger 6 Disconnect the charger from the mains Connection data 230 V 50 Hz Notice Ch...

Page 125: ...ttery capacity If the drive system is switched on the drive is activated as soon as the pedals are moved with sufficient force 6 20 2 Switching off the electric drive system The system switches off automatically ten minutes after the last command The drive system can also be switched off on the battery Press On Off button battery for 6 seconds Crash caused by lack of readiness for braking When it ...

Page 126: ...itch Y 2 switch control panel Figure 137 2 switch control panel 1 Switch X 2 Switch Y Crash caused by distraction A lack of concentration 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 the pedelec if you want to make inputs on the on board computer other than change the level of assista...

Page 127: ...levels of assistance are available Press switch Y left once to increase the level of assistance Press switch X left to reduce the level of assistance Switch Function WHEN RIDING X Change up Y Change down A Switch between automatic and manual Gear shift Switch Function WHEN RIDING X Increase level of assistance Y Reduce level of assistance A Switch journey data displayed WHEN ADJUSTING X Move curso...

Page 128: ...Y left is not pushed for longer than one minute the level of assistance is reset to the level of assistance used previously 6 21 4 Switching the journey information The displayed journey information can be switched Figure 140 Changing from main display screen to DST display example Press the button display or switch A until the required journey information is displayed The sequence is as follows 1...

Page 129: ...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 130: ...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 131: ... the deflection stroke speed is reduced Efficiency on hilly and flat terrain is improved Figure 143 Changing compression adjuster to a harder setting Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed is increased Sensitivity to small bumps is increased Figure 144 Changing compression adjuster to a softer setting ...

Page 132: ...anging gears This makes it easier to switch gears and reduces wear on the drivetrain 6 24 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 145 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 133: ...th open stem clamping lever Notice Heat or direct sunlight can cause the tyre pressure to increase above the permitted maximum pressure This can destroy the tyres Never park the pedelec in the sun On hot days regularly check the tyre pressure and adjust it as necessary Moisture penetrating at low temperatures may impair individual functions due to the open structural design Always keep the pedelec...

Page 134: ...Pull handlebars into highest possible position Figure 147 All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 148 All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever ...

Page 135: ... 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 136: ... Section 7 3 7 1 Care for leather handles see Section 7 4 8 2 Clean the leather saddle see Section 7 3 9 1 Care for leather saddle see Section 7 4 11 Clean handlebars see Section 7 3 6 Cleaning the motor see Section 7 3 3 Clean hub see Section 7 3 12 Cleaning the frame see Section 7 3 4 Clean tyres see Section 7 3 10 Check back pedal brake see Section 7 5 2 5 Clean saddle see Section 7 3 9 Clean s...

Page 137: ... 1 Care for handlebars see Section 7 4 7 Check handlebars see Section 7 5 5 Check light see Section 7 5 3 Care for hub see Section 7 4 12 Check hub gear see Section 7 5 9 2 Check nipple holes see Section 7 5 1 4 Care for pedals see Section 7 4 15 Check pedal see Section 7 5 7 Care for frame see Section 7 4 1 Check belt tension see Section 7 5 9 Check saddle see Section 7 5 6 Care for shifter see S...

Page 138: ...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 139: ... 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 140: ...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 141: ...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 142: ...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 52 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 143: ...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 144: ...ge 3 Rinse off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 13 7 3 12 Hub 1 Put on protective gloves 2 Remove dirt from hub with a sponge and soapy water 3 Rinse off component with water from a watering can 4 Wipe off oily dirt with a degreaser and a cloth 7 3 13 Switching elements 1 Clean gear shift shift cables and transmission with water a bru...

Page 145: ...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 146: ...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 53 Required tools and cleaning agents for servicing 2 y x 1 3 A A A Battery terminal grease Notice Hard wax polish and protection...

Page 147: ...ply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point with a cloth 4 If you have a Speedlifter Twist also apply oil to the unlocking bolt groove in the Speedlifter body 5 Apply a little acid free lubricant grease between the stem quick release lever and the sliding piece to reduce the quick release lever operating force 6 If you have a stem with a cone clamp app...

Page 148: ...are products keep leather smooth and resistant brighten its appearance and improve or replace stain protection 1 Try leather care product out on a less visible spot before use 2 Care for leather saddle from below with a leather care product Only care for the top of leather saddles with a leather care product if they are badly worn and dried out 3 Avoid wearing light coloured trousers after care du...

Page 149: ...of oil 3 Remove any surplus lubricant with a clean cloth 4 Spray metal foot rests with silicone spray 7 4 16 Caring for the chain Place newspaper or paper towels underneath to collect chain oil 1 Lift rear wheel 2 Turn the crank briskly in an anti clockwise direction 3 Use slight finger pressure to the chain oil bottle to apply a wafer thin thread of oil to the chain links The faster the crank is ...

Page 150: ...point in time 5 Leave chain oil to penetrate into the chain links for a few hours or overnight 7 4 17 Caring for the battery Grease plug terminals on the battery with terminal grease or contact spray from time to time 7 4 18 Caring for the brake 7 4 18 1 Caring for the brake Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precisi...

Page 151: ...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 152: ... 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 153: ...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 153 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 154 Examples of fatigue c...

Page 154: ...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 155: ...5 9 8 Contact your specialist dealer if the pressure point cannot be reached 7 5 2 2 Checking the hydraulic system 1 Push the brake lever and check whether any brake fluid leaks out of the lines connections or on the brake linings If any brake fluid leaks from anywhere take pedelec out of service Contact specialist dealer 2 Push brake lever and hold several times If you are unable to clearly detec...

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

Page 158: ...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 159: ...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 160: ... 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 161: ...es on the shifter housing There is noticeable play of 2 to 5 mm 1 2 gear when you turn the twist grip Figure 162 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 162: ...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 163: ... 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 164: ...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 165: ...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 166: ... 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 167: ...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 168: ...ce a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care for Section 7 4 12 O K Untreated Treat Hub with cone bearing optional Once a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care for Section 7 4 12 O K Untreated Treat 6 months Check mount fastening O K Loose rust Retighten screws new handlebars as specified in parts list if necessary Once a year Adjust O K Not ad...

Page 169: ...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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...Remove outer sleeve from the seat post remote control Figure 168 Removing the cartridge 4 Use a 5 mm to undo Postpin axle and pull out Figure 169 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 170 Pulling the cartridge out 6 Hold the cartridge with one hand at the height of the mechanism and pull the Bowde...

Page 180: ... Pull slide bushing tube out of the seat tube Figure 174 Removing the outer sleeve and slide bushing Caring for the outer sleeve 1 Detach spring washer or outer sealing ring Figure 175 Removed spring washer 2 Carefully remove the wiper from the groove Figure 176 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 181: ...inserting and fastening the wiper Cleaning the slide bushing 1 Clean the slide bushing tube with a damp cloth Figure 181 Cleaning the slide bushing tube Increasing the air pressure 1 Use 3 mm hex spanner to unscrew valve cap Figure 182 Unscrewing the valve cap 2 Screw valve adapter into mounting interface from below Figure 183 Screwing the valve adapter in 3 Use compression pump to pump the cartri...

Page 182: ... interface against twisting with a 24 mm open end spanner Figure 187 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 188 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 189 Fastening the cartridge valve lid Notice ...

Page 183: ...rrect Bowden cable 4 Carefully push cartridge into the seat tube Pull the Bowden cable out of the frame to help Figure 194 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 184: ...unting hole in the outer sleeve Turn outer sleeve into the right position Figure 199 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 200 Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper Figure 201 Pushing the seat p...

Page 185: ...206 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 207 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 186: ...r sleeve with a cloth Figure 213 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 214 Inserting the felt ring 13 ...

Page 187: ...your hand until it will go no further Figure 218 Pulling the seat post out 3 Clean the seat post longitudinal grooves with a damp cloth Figure 219 Cleaning the longitudinal groove 4 Apply grease into the longitudinal groove and on both cross pieces Figure 220 Applying grease 5 Push seat post together Figure 221 Pushing the seat post together 6 Push the height adjustment operating lever backwards F...

Page 188: ...come damaged Figure 224 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 225 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 189: ...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 190: ...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 191: ...battery for at least 8 seconds 14 If the drive system won t start after about 6 seconds press the On Off button battery for at least 2 seconds 15 If the drive system still won t start contact your specialist dealer 9 1 2 RD protection reset The rear derailleur protection function will immediately trigger to protect the system if the pedelec is exposed to a strong impact due to a fall for example T...

Page 192: ...ton to switch it on The assisted 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 charge level 2 Recharge the battery if it is almost flat The battery does not perform as well in winter weather This is not a malfunction The battery is a consumable Repeated charging and long periods of u...

Page 193: ...th to clean the connection terminals 2 Start charging 3 If the battery still won t charge contact your specialist dealer The battery does not start charging when the charger is connected The battery may be at the end of its service life Replace battery with new one The battery and charger become hot The temperature of the battery or the charger may have exceeded the operating temperature range 1 I...

Page 194: ...ta is shown on the monitor when the On Off button battery is pressed The battery charge level may be insufficient Charge the battery Is the power switched on Press the On Off button battery to switch the power on Is the battery charged If the battery is fitted to the pedelec and is being charged it cannot be switched on Interrupt charging process Is the connector fitted to the power cable correctl...

Page 195: ...ronic gear shift 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 specialis...

Page 196: ...ed way This impairs traction and control blue line Fork head and handlebars are deflected upwards if the wheel bounces back from the ground Body weight may be thrown up and backwards in an uncontrolled way green line Figure 228 Suspension fork rebounding too quickly Solution Figure 229 Turning the rebound screw damper towards tortoise symbol Turn the rebound screw clockwise damper towards the tort...

Page 197: ...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 impact green line Figure 230 Suspension fork rebounding too slowly Solution Figure 231 Turning the rebound screw damper towards hare symbol Turn the rebound screw anti clockwise tow...

Page 198: ...the rider s weight shifts forward and the pedelec loses some momentum Figure 232 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 233 Changing compression adjuster to a harder setting Turn compression adjuster clockwise The damping and compression hardness is increased and the deflection stroke speed is reduced Efficiency on hilly and flat terrain is improved ...

Page 199: ... wheel no longer touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 234 Excessively hard damping in the suspension fork on bumps Solution Figure 235 Changing compression adjuster to a softer setting Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed is increased Sens...

Page 200: ...rolled speed at which the damper rebounds after deflecting blue line Saddle and handlebars are deflected upwards when the wheel bounces back from the ground The rider s body weight may be shifted upwards and forwards if the damper fully rebounds too quickly green line Figure 236 Rear frame damper rebounding too quickly Solution Figure 237 Position and shape of the rebound adjuster red depends on t...

Page 201: ...nd return to the initial position again The available deflection and traction are reduced blue line The rear frame damper remains in a deflected state after contact with the first bump When the rear wheel hits the second bump the saddle follows the path of the rear wheel instead of remaining in a horizontal position The available deflection and potential absorption of bumps are reduced which cause...

Page 202: ...s quickly used up the rider s weight shifts forward and the pedelec loses some momentum Figure 240 Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 241 Position and shape of the compression adjuster blue depends on the model Turn compression adjuster clockwise The damping and compression hardness is increased and the deflection stroke speed is reduced 1 2 ...

Page 203: ...der are deflected upwards and forwards the rear wheel loses contact with the ground and control is reduced green line Figure 242 Excessively hard damping in the rear frame damper on bumps Solution Figure 243 Position and shape of the compression adjuster blue depends on the model Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke spee...

Page 204: ... new components 9 6 2 Replacing the lighting Only use components of the respective power class for replacement 9 6 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 6 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 205: ...damaged battery and the charger can be returned to any specialist dealer free of charge Further disposal options may be available depending on the region Store the individual parts of the decommissioned pedelec in a dry place free from frost where they are protected from direct sunlight 10 1 Removal of waste guidelines Waste type Disposal Non hazardous waste Recycling Waste paper cardboard Return ...

Page 206: ...il Cleaning cloths daubed in oil Lubrication oil Gear oil Lubricating grease Cleaning fluids Kerosene White spirit Hydraulic fluid Brake fluid Never mix different oil fluids Store in original container Small quantities usually 30 kg Take to municipal collection points for hazardous waste e g mobile toxic waste collection service Larger quantities 30 kg Collection by waste disposal companies Paints...

Page 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...MY22H03 32_1 0_04 10 2021 211 Notes ...

Page 213: ...SL M8100 Shifter Front derailleur Cassette cassette sprocket SHIMANO Deore CS M6100 10 51T Chain SHIMANO CN M6100 Belt Front brake SHIMANO XT BR M8100 Hydraulic disc brake Rear brake SHIMANO XT BR M8100 Hydraulic disc brake Brake lever front rear SHIMANO BL M8100 Disc front SHIMANO SM RT64 203 mm Disc rear SHIMANO RT EM600 203 mm lock ring Wheel set front rear CRANKBROTHERS Crankbrothers Synthesis...

Page 214: ...ble Not yet available when the instructions were produced Lock ABUS ABUS IT1 Plus Battery lock Stand stand mount Motor SHIMANO EP8 DU EP800 250 Watt 85 Nm Rechargeable battery SIMPLO 630 On board computer SHIMANO EP8 with EP8 switch Charger SIMPLO 2 A ...

Page 215: ...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 216: ...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 217: ...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 218: ...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 219: ...chinery Directive 2006 42 EC The following harmonised standards have been applied ISO 20607 2018 Safety machinery Instruction handbook General drafting principles EN 15194 2017 Cycles Electrically power assisted cycles EPAC Bicycles The following other technical standards have been applied EN 11243 2016 Cycles Pannier racks for bicycles Requirements and test methods Cologne 19 04 2021 Georg Honkom...

Page 220: ...T EM300 RT EM600 SM CN910 12 FC EM600 FC M8150 FC EM900 SM CRE80 B SM CRE80 SM CRE70 SM CRE70 B SM CRE70 12 SM CRE80 12 B SM CRE80 12 SB SM CRE61 SM CDE80 CD EM800 MU UR500 BM E8016 BM E8020 BM E8030 A BM E8030 B BM E8031 A BM E8031 B BT E8016 BT E8010 BT E8014 BT E8020 BT E8036 BT E8035 BT E8035 L EW SW300 EW SW100 EW CP100 EC E6000 EC E6002 EC E8004 SM BCC1 EW SD300 EW SD50 EW AD305 EW JC302 EW ...

Page 221: ...MY22H03 32_1 0_04 10 2021 220 Appendix ...

Page 222: ...szövege elérhető a következő internetes címen http si shimano com Polski Polish SHIMANO INC niniejszym oświadcza że typ urządzenia radiowego SC EM800 jest zgodny z dyrektywą 2014 53 UE Pełny tekst deklaracji zgodności UE jest dostępny pod następującym adresem internetowym http si shimano com Português Portuguese O a abaixo assinado a SHIMANO INC declara que o presente tipo de equipamento de rádio ...

Page 223: ...dards DA105949 Brazil 00243 16 04304 Fabricado no Japão Este produto contém a placa SWAN 2 código de homologação 00243 16 04304 Este produto está homologado pela ANATEL de acordo com os procedimentos regulamentados pela Resolução 242 2000 e atende aos requisitos técnicos aplicados Para maiores informações consulte o site da ANATEL http www anatel gov br Este equipamento opera em caráter secundário...

Page 224: ...ntaining 151 158 servicing 148 Charger disposing of 204 Chassis 26 Child seat 116 Compression adjustment 30 Compression damper 31 Control panel cleaning 141 Crown 31 D Dimensions 57 Direction of travel 41 Disc brake 39 Display 44 charging the battery 108 115 125 Drive system 41 switching off 124 switching on 124 mechanical 41 Dust seal 31 E Electrical cable checking 156 Emergency stop system 17 F ...

Page 225: ...25 121 changing the saddle tilt 75 changing the seat length 77 cleaning 142 determining the saddle height 75 77 using 121 Sag Setting wheel 31 Seat post 25 40 cleaning 142 servicing 147 Shifter cleaning 143 servicing 148 Spoke nipples 37 servicing 147 Spoke 36 Stanchion 31 Steering headset 26 Steering system 26 Stem 26 checking 157 cleaning 142 servicing 146 Suspension fork cleaning 140 servicing ...

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