Whyte E-150 User Manual Download

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Summary of Contents for E-150

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Page 2: ...TB Full Suspension Bike Range Page 3 Whyte Supplementary Service Manual Page 37 BOSCH Drive Unit Page 45 BOSCH PowerTube Battery Page 57 BOSCH Charger Page 67 BOSCH Purion Display Page 75 BOSCH Error codes ...

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Page 4: ...mbling Other Rear Suspension Bearings 6 2 1 Extraction of Bearings 6 2 2 Insertion of Bearings 6 2 3 Re Assembly of Shield Washers Spacers 6 3 Re assembling the Rear Suspension 6 3 1 Re Assembly of the Rear Suspension 6 3 2 Insert the bearings into the Main Frame plus assemble the chain stays to the Main Frame 6 3 3 Re assemble the other rear suspension parts 6 3 4 Re assemble the Rear Shock into ...

Page 5: ...not ride it and instead arrange for a professional bicy cle mechanic at your local Whyte dealer to do the job correctly Bundled with this manual are the respective manufacturers instructions and manuals for the branded parts and systems that are fitted to your Whyte bike Please take time to study all the relevant instruction manuals to ensure you have a continually safe and well set up bike before...

Page 6: ...ou Whyte bike then DO NOT RIDE YOUR BIKE Contact your Whyte dealer who will be able to advise you on how to go about setting up you Whyte bike for riding and or making adjustments to the components fitted to your Whyte bike 3 2 WHYTE INTER GRIP SEAT CLAMP ADJUSTMENT SERVICE Tools Required 5mm Hex Key Torque Wrench Ranging from 3Nm to 15Nm SKF LGEP2 or Castrol Spheerol AP3 or Finish Line Teflon Whi...

Page 7: ...e that allows the dropper Seat Post to function correctly CAUTION When adjusting the saddle height you MUST obey the Minimum insertion depth requirement marked on the Seat Post Also consult the manu facturers Seat Post instructions in conjunction with these notes 3 3 SET UP OF FORK Tools Required Good Quality Shock Pump Small Ruler The Front Suspension Fork fitted to your Whyte bike will be pre se...

Page 8: ... and not plush then the re bound damping is too fast A bit of trial and error is needed to get the exact setting IMPORTANT SAFETY NOTE Always stop riding when making adjustments of any kind to the bicycle 3 4 SET UP OF REAR DAMPER Tools Required Good Quality Shock Pump Small Ruler Your Whyte bike is fitted with either an air spring or a coil spring rear Shock This means that for an air Shock the a...

Page 9: ... to your Whyte bike may have a platform facility to adjust the slow speed compression damping eg Fox 3pos w Adj or SRAM RockShox Motion Control Please refer to the relevant shock manufactures technical information to learn how to adjust these features Please note that the Whyte rear suspension systems have been designed not to rely on excessive low speed compression damping to obtain efficient ped...

Page 10: ...a component has been exceeded it may fail suddenly causing possible injury to the rider Any form of crack scratches and decolouring in high stress are as are showing that the component has exhausted its life time and has to be replaced If you are in any doubt about one or more components on your Whyte DO NOT RIDE YOUR BIKE Consult the specific component manu facturers literature or take your bike ...

Page 11: ...ll parts on a Whyte bicycle please refer to the specific component manufacturers detailed instructions bundled with this manual or for further information visit the specific manufacturers website 6 0 SERVICING THE REAR SUSPENSION 6 1 Remove the Rear Shock Links Swinging Arm Tools Required 2x 4mm Hex Key 1x 5mm Hex Key Ball ended 1x 6mm Hex Key 1x 8mm Hex Key 2x T 25 Torx Keys WHYTE Service Manual ...

Page 12: ...mm A F Internal Hex 10 M6 x 20mm long Capscrew 5mm A F Internal Hex 11 Tapered Sleeve for Expanding Collet 12 Pivot Pin 80mm long expanding collet M15 thread 13 M15 x 26mm long Pivot Screw 10mm Thread 6mm A F Internal Hex 14 Chain stays 15 Main Frame 16 Rear Suspension H Link 99mm centre to centre 17 M15 x 25mm long Pivot Screw 10mm Thread 6mm A F Internal Hex 18 Seat stays 19 Shield Washer O D 23...

Page 13: ...do the two M5 x 16mm long Socket head Capscrews 1 from the Ø8mm x 31mm long Hollow Pivot Pin 3 that passes through the Main Frame 15 and front of the Rear Shock 6 Which ever Capscrew 1 becomes undone first remove it and the adjacent Collar 2 and pull the Pivot Pin 3 all the way out from the other side Using the 6mm Hex Key and the 8mm Hex Key undo and remove both the Flanged Nut M12 x 19mm long 4 ...

Page 14: ... 3 Figure 7 ready for re assembly To separate the Seat stays 18 from the H Link 16 and Main Frame 15 whilst referencing figure 4 using the 6mm Hex Key unscrew and remove the two M15 x 26mm Flanged alloy Screws 13 at the front of the Seat stays 18 The Seat stays 18 may now be removed from the H Link 16 Finally to remove the Shock Extender 7 from the H Link 16 using the 6mm Hex Key unscrew and remov...

Page 15: ...in 80mm long expanding collet M15 thread 12 The capscrew 10 may now be completely removed to allow the tapered sleeve 11 to be released from the collet 12 The Chain stays 14 may now be removed from the Main Frame 15 Be careful to retain the two Shield Washers 19 ready for re assembly Using the press tools shown in Figure 19 extract the BOLU WB0025 bearings 20 from both sides of the Main Frame 15 A...

Page 16: ...R BEARINGS Reference figures 6 7 Figure 6 Assembly of Link Item Description 1 ID 15mm OD 24mm Width 5mm bearing BOLU WB0025 2 Shield washer O D 20mm 3 Shield washer O D 23mm 4 Various centre to centre dimensions Alloy Link Bodies WHYTE Service Manual ...

Page 17: ...gure 7 Assembly of the Seat stays Item Description 1 ID 15mm OD 24mm Width 5mm bearing BOLU WB0025 2 Middle shield washer O D 20mm 3 Outer shield washer O D 23mm 4 Right Seat stay 5 Left Seat stay WHYTE Service Manual ...

Page 18: ...RS MAX Link or Rear of Seat Stay Item Description 1 M8 Capscrew ISO4162 55 long 2 M8 Washer ISO 7089 3 M8 Nut ISO 4032 4 BOLU WB0025 Bearing 5 BOLU WB0025 Bearing Tool 1 6 Mating Component ie Link or Seat Stay 7 BOLU WB0025 Bearing Tool 2 WHYTE Service Manual ...

Page 19: ...2RS MAX Above Main Frame Bottom Bracket Item Description 1 M8 Capscrew ISO4762 55 long 2 M12 Nut ISO 4035 3 I D 12 Washer ISO 7089 4 BOLU WB0025 Bearing 5 BOLU WB0025 Bearing Tool 1 6 Mating Component ie Bottom Bracket Yoke 7 BOLU WB0025 Bearing Tool 2 8 Internal Bearing Spacer ...

Page 20: ...he inside bore of the mating component 6 Next assemble the components as illustrated in either Figure 8 or 9 It is very important to make sure the Bearing 4 and Bearing Insertion tool 1 5 are squarely seated against the mating component 6 With great care slowly tighten the M8 Socket head cap screw 6 with the 6mm Hex Key and the nut 2 with the 13mm Spanner until you can see the Bearing 4 being pres...

Page 21: ...ures 3 4 5 6 10 The re assembly of the Rear Suspension is essen tially the reverse of the dis assembly procedures 6 1 1 6 1 2 6 1 3 6 3 2 To re assemble the Chain stays 14 and Bearings 20 into the Main Frame 15 First Stage Before inserting the Bearings make sure all the components are clean from dirt and have been thoroughly de greased Apply a small amount of Loctite 638 to the out side diameter o...

Page 22: ... 7 Then ensure that the Shield Washers in the Link 16 are not pushed out as you place the Shock Extender 7 inside them Then pass an M15 x 25mm long Flanged alloy Screw 17 through the H Link 16 the Bear ing in Link See item 1 figure 6 the adjacent Shield Washer into the thread of one arm of the Shock Extender 7 Using a 6mm Hex Key Torque tighten the M15 Flanged alloy Screw 17 to the recommended Tor...

Page 23: ...ong 4 into the Flanged Screw M12 x 15mm long 5 to the recommended Torque settings refer to the Tightening Torque settings in Section 10 0 Wipe off any excess grease from around both ends of the Shock 6 Make sure that the Ø8mm holes in the Main Frame 15 and the front of the Rear Shock 6 are all concentric with each other and push the Ø8mm x 31mm long Hol low Pivot Pin 3 all the way through Place a ...

Page 24: ...Reference figure 11 Loosely assemble all the parts as shown making sure the screws 1 3 are correctly positioned be very careful not to cross thread this on it s way in Insert the Rear Wheel and the Shimano E Thru Rear Axle Adjust the Axle as per the Shimano Technical Service Instructions SI 27U0A 001 00 Whilst adjusting the Rear Axle make sure the nose of the M5 Grub Screw 3 is aligned with one of...

Page 25: ...ed in Section 10 0 Also tighten the M5 Countersunk Head Screw 2 DO NOT OVERTIGHTEN since the thread of the Screws 2 3 are very small Finally if necessary re adjust the SRAM Maxle Rear Axle as per the SRAM User Manual 95 4315 004 000 Item Description 1 M4 x 16mm long Countersunk Head Screw 2 Rear Derailleur Hanger for Shimano E Thru Direct Mount Grey Colour 3 M4 x 8 long Grub Screw 4 Axle Nut for S...

Page 26: ...M Maxle 148mm Gunmetal Col our 2 M5 x 16mm long Countersunk Head Screw 3 M4 x 12mm long Countersunk Head Screw 4 Rear Derailleur Hanger for SRAM Maxle 148mm Black Colour 5 M4 x 8 long Grub Screw 6 Axle Nut for SRAM Maxle 142mm Black Colour Figure 12 Whyte Dropout Assembly For SRAM Maxle 148mm 18 ...

Page 27: ...in the specified order Figures 22 to 23 From the right side of the Main Frame 6 unscrew remove the M6 x 30mm long Capscrew 1 Replace that with the longer capscrew and screw loosely into the Threaded Sleeve 5 Figures 24 25 Push the Threaded Sleeve 5 all the way out of the opposite side of the Main Frame 6 Figures 26 to 27 Move to the left side of the Main Frame 6 Place the M6 x 30mm long Capscrew 1...

Page 28: ...ain Sleeve 2 Also place some grease onto the threaded end of the M6 Capscrew 1 Figures 30 31 Place the Grip Pad 4 into the hole in the Main Frame 6 such that the curved face is towards the seat tube in the Main Frame 6 Insert the Seat Post 7 to help align the Grip Pad 4 Figures 32 33 From the left side of the Main Frame 6 insert the Plain Sleeve 2 and make sure the 45 angled edge on the Plain Slee...

Page 29: ... since too much force will damage them 9 1 To replace cable or hose outers Reference figures 36 to 41 When replacing outer cables and or brake hoses most of the holes in the frame are large enough 25mm long x 8mm wide simply to manipu late the outer cable or brake hose into or out of the hole However the two holes for the rear derailleur cable in the chain stay are necessarily small therefore the ...

Page 30: ...nt of the chain stay Then manipulate both the inner cable and the outer cable whilst also pushing the outer cable forwards with a lot of force and the outer cable should also find the exit hole Figure 41 Push the outer cable all the way through the exit hole and finally re move the inner cable 9 2 To fit a Dropper seat post with internal hose Take care to abide by safety recommendations Figure 42 ...

Page 31: ... into the down tube and push the hose up towards the head tube The grommets will have to be pushed further along the hose to do this Reference figure 48 Prise out the rubber grommet on the side of the down tube near the head tube with a small screwdriver Reference figure 49 Manoeuvre the hose end out of the slot at the top of the down tube Use a small hook to assist with capturing the hose end and...

Page 32: ... Torque Wrench Ranging from 3Nm to 15Nm Tip Take care to position the bicycle in a suitable work stand clear of the ground to enable the removal of the battery To remove the battery from the bicycle frame using the T 25 Torx tool remove the T 25 Torx bolt 1 from the Bottom Cover 2 It may be necessary to clean out the head of the T 25 Torx bolt 1 if the bike has been ridden so that the T 25 Torx to...

Page 33: ...nsult the on line Bosch resources to fully understand how to handle and store your Bosch Battery at all times To Refit the Bosch Battery 6 is the reverse of the removal process Slide the Bosch Battery 6 back into the Down Tube 3 IMPORTANT Ensure that the Bosch Battery 6 is in the correct orientation see Figure 55 Failure to correctly orientate the battery will result in the Bosch Connector Block 5...

Page 34: ...vely refer to the specific manufacturers website for further information Tools Required Torx T 25 Torque Wrench Ranging from 3Nm to 15Nm See Figure 54 and Figure 56 If you are required to start the eBike system using the On Off button located on the Bosch Battery 6 follow the instructions in Sec tion 10 1 to remove the Bottom Cover 2 from the Down Tube 3 You will then reveal the Access Hole 7 in t...

Page 35: ...e Bosch Battery has been integrated into the top of the Motor Mount as can be seen in Figure 57a and 57b To access the charge port peel back the sealed cover of the Charge Port marked Whyte Energy to reveal the charge port Follow the instructions contained in the Bosch Battery In struction Manual to Charge the Battery When Charging has finished re fit the Re mote Charge Port Cover and press firmly...

Page 36: ...1 Min 7 5 Max M6 x 20 long Socket Head Capscrew 9 0 Min 11 0 Max 6 1 Min 7 5 Max Rear Dropout Assemblies M4 Countersunk Screws 4 2 Min 4 6 Max 3 1 Min 3 4 Max M5 Countersunk Screws 4 8 Min 5 2 Max 3 6 Min 3 8 Max M5 Grub Screw 2 2 Min 2 6 Max 1 6 Min 1 9 Max Seat Post Clamp M6 Cap Screw 12 Min 14 Max 8 9 Min 10 3 Max 11 0 TORQUE SETTINGS Torque explained If no suitable Torque Wrench is available a...

Page 37: ...Page 36 2019 WHYTE Service Manual 12 0 OWNER S NOTES ...

Page 38: ...Performance Line Cargo Line BOSCH en Original operatinginstructions 37 ...

Page 39: ...2 0 275 007 XD4 12 02 2019 Bosch eBike Systems 5 17mm 1 2 3 A ...

Page 40: ...it Under extreme conditions such as continuously high torques at low travel speeds or when riding up hills or carrying loads the housing may reach a very high tem perature The temperature that the drive unit housing may reach is influenced by the following factors Ambient temperature Ride profile route gradient Ride duration Assistance modes User behaviour personal effort Total weight rider eBike ...

Page 41: ...egulations not possible in all country specific models via the eBike battery B When changing the bulbs ensure that they are compatible with the Bosch eBike system ask your bicycle dealer and are suitable for the specified voltage Bulbs must only be replaced with bulbs of the same voltage Inserting a bulb incorrectly can cause it to blow Assembly Inserting and removing the battery For inserting and...

Page 42: ... moved for approx 10 min and no button is pressed on the on board computer the eBike system switches off automatically in order to save energy eShift optional eShift is the integration of electronic gear shifting systems into the eBike system The eShift components are electric ally connected to the drive unit by the manufacturer The separate operating instructions describe how to operate the elect...

Page 43: ... without as sistance at any time either by switching off the eBike system or by setting the assistance level to OFF The same applies when the battery is drained Interaction between the eBike system and gear shifting The gear shifting should be used with an eBike drive in the same way as with a normal bicycle observe the operating in structions of your eBike on this point Irrespective of the type o...

Page 44: ...y questions about the eBike system and its components contact an authorised bicycle dealer For contact details of authorised bike dealerships please visit www bosch ebike com Disposal The drive unit on board computer incl operat ing unit battery speed sensor accessories and packaging should be disposed of in an en vironmentally correct manner Do not dispose of eBikes and their components with hous...

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Page 46: ...en Original operating instructions PowerPack 300 400 500 PowerTube 400 500 625 BBS245 BBR245 BBS265 BBR265 BBS275 BBR275 BBP280 BBP281 BBP282 BBP283 BBP290 BBP291 45 ...

Page 47: ...2 0 275 007 XPX 20 12 2018 Bosch eBike Systems 13 12 2 1 6 5 3 4 11 4 3 7 6 5 8 13 12 9 ...

Page 48: ... 3 Bosch eBike Systems 0 275 007 XPX 20 12 2018 16 14 12 13 11 4 3 14 6 5 4 15 ...

Page 49: ...4 0 275 007 XPX 20 12 2018 Bosch eBike Systems 7 B A 8 9 5 1 6 5 7 2 6 10 10 ...

Page 50: ... 5 Bosch eBike Systems 0 275 007 XPX 20 12 2018 1 2 1 2 4 3 5 14 6 15 6 5 14 15 15 C D ...

Page 51: ...6 0 275 007 XPX 20 12 2018 Bosch eBike Systems ...

Page 52: ...y may give off fumes if it becomes damaged or is used incorrectly Ensure the area is well ventil ated and seek medical attention should you experi ence any adverse effects The fumes may irritate the respiratory system u Only charge the battery using original Bosch chargers When using chargers that are not made by Bosch the risk of fire cannot be excluded u Use the battery only in conjunction with ...

Page 53: ...k mounted battery Li ion battery PowerTube 400 PowerTube 500 PowerTube 625 Product code BBP282 horizontal BBP283 vertical BBP280 horizontal BBP281 vertical BBP291 horizontal BBP290 vertical Rated voltage V 36 36 36 Nominal capacity Ah 11 13 4 17 4 Energy Wh 400 500 625 Operating temperature C 5 to 40 5 to 40 5 to 40 Storage temperature C 10 to 60 10 to 60 10 to 60 Permitted charging temperature ra...

Page 54: ...will cause a short circuit see figures A and B Charging process for two batteries If two batteries are fitted to an eBike both batteries can be charged using the uncovered connection To begin with both batteries are charged one after the other until they reach approx 80 90 capacity then they are both charged at the same time until full the LED flashes on both batteries When the bike is in operatio...

Page 55: ...ndicator 3 will light up Whether the eBike system is switched on is only visible on the on board computer To switch off the battery press the on off button 4 again The LEDs on the indicator 3 will go out This will also switch the eBike system off If no power is drawn from the eBike drive for about 10 minutes e g because the eBike is not moving and no button is pressed on the on board computer or t...

Page 56: ...hird parties e g air transport or forwarding agency special re quirements on packaging and labelling e g ADR regula tions must be met When preparing items for shipping a dangerous goods expert can be consulted as required Do not ship batteries if the housing is damaged Apply tape over exposed contacts and pack the battery such that it can not move around inside the packaging Inform your parcel ser...

Page 57: ...English 6 0 275 007 XPX 20 12 2018 Bosch eBike Systems ...

Page 58: ...en Original operating instructions Charger BCS220 BCS230 BCS250 57 ...

Page 59: ...ies Input 230V 50Hz 2 15A Output 36V 6A Made in Vietnam Robert Bosch GmbH Reutlingen Fast Charger BCS250 eBike Battery Charger 36 4 230 0 275 007 907 Li Ion Use ONLY with BOSCH Li Ion batteries Input 230V 50Hz 1 5A Output 36V 4A Made in PRC Robert Bosch GmbH Reutlingen Standard Charger BCS220 Standard Charger Fast Charger 2 3 1 5 4 ...

Page 60: ... 3 Bosch eBike Systems 0 275 007 XCX 24 04 2018 BCS230 Compact Charger 2 5 1 3 4 ...

Page 61: ...4 0 275 007 XCX 24 04 2018 Bosch eBike Systems 9 10 2 2 3 11 8 6 6 5 A B ...

Page 62: ... 5 Bosch eBike Systems 0 275 007 XCX 24 04 2018 8 5 6 7 7 5 6 11 C ...

Page 63: ...6 0 275 007 XCX 24 04 2018 Bosch eBike Systems 5 6 D ...

Page 64: ...ure the battery is completely dry and placed on a fireproof surface before charging There is a risk of fire due to the heat generated during charging u The eBike battery must not be left unattended while charging u Supervise children during use cleaning and mainten ance This will ensure that children do not play with the charger u Children or persons who owing to their physical sensory or mental l...

Page 65: ... Plug the charging connector 5 of the charger into the socket 6 on the battery Charging the battery on the bike see figures C and D Switch the battery off Clean the cover of the charging socket 7 Avoid getting dirt e g sand or soil in the char ging socket and contacts in particular Lift the cover of the charging socket 7 and plug the charging connector 5 into the charging socket 6 u Charge the bat...

Page 66: ...ttery from the charger until the charging temperature range has been reached Do not reconnect the battery to the charger until it has reached the correct charging temperature The charger is not charging No LEDs flashing one or more LEDs will remain per manently lit depending on the state of charge of the eBike battery Contact an authorised bike dealership Charging not possible no indicator on batt...

Page 67: ...English 4 0 275 007 XCX 24 04 2018 Bosch eBike Systems ...

Page 68: ...en Original operating instructions Purion BUI210 BUI215 67 ...

Page 69: ...W W W W W W W W W W WA WA WA WA W WA WA WA WA W WA W W W WA WA WA WA WA WA WA WA WA WA WAL WAL WAL WA WA A A WAL WAL WAL AL WAL AL AL WAL AL WAL AL AL AL L L L L ALK ALK ALK WA WA A WA WA WAL ALK AL AL L L ALK ALK ALK ALK ALK ALK K K K K ALK ALK ALK ALK ALK K K ALK ALK ALK LK K K K LK LK LK K ALK ALK ALK K ALK ALK ALK 7 6 5 j i a b c d e h g f 8 9 1 2 3 4 ...

Page 70: ...WA WA W W W W W W W W W W W W W W W WA WA WA WA W WA WA WA WA W WA W W W WA WA WA WA WA WA WA WA WA WA WAL WAL WAL WA WA A A WAL WAL WAL AL WAL A AL WAL WAL AL AL AL L L L L ALK ALK ALK WA WA A WA WA WAL ALK AL AL LK L ALK ALK ALK ALK ALK ALK K K K K ALK ALK ALK ALK ALK K K ALK ALK ALK LK K K K LK LK LK K ALK ALK ALK K ALK ALK ALK A 3 4 10 ...

Page 71: ...4 1 270 020 XBP 11 02 2019 Bosch eBike Systems ...

Page 72: ...ents shown refers to the illus trations on the graphics pages at the beginning of the manual Individual illustrations in these operating instructions may differ slightly from the actual conditions depending on the equipment of your eBike 1 On off button for on board computer 2 Push assistance button WALK 3 Fastening screw for on board computer 4 Holder for on board computer 5 Decrease assistance l...

Page 73: ...er to avoid damage Energy supply of the on board computer The on board computer is supplied with voltage by two CR2016 button cells Changing the batteries see figure A If the on board computer shows LOW BAT on the display remove the on board computer from the handlebars by un screwing the fastening screw 3 of the on board computer Open the battery compartment cover 10 using a suitable coin remove ...

Page 74: ...ntil the re quired assistance level appears on the indicator i To de crease the assistance level briefly press the button 5 If the display is set to TRIP TOTAL or RANGE the selected assistance level will only be superimposed briefly for ap prox one second on the display when switching over Switching bicycle lights on off For the model which has the bike lights powered by the eBike system a medium ...

Page 75: ...ow RESET If you continue to press both buttons the trip distance TRIP will be set to 0 To reset the range of the battery RANGE select the battery range RANGE and simultaneously press and hold the but tons and The display will initially show RESET If you continue to press both buttons the trip distance TRIP will be set to 0 You can switch the displayed values from kilometres to miles by holding dow...

Page 76: ...n board computer is flat Charge the on board computer in the holder or via the USB port 431 Software version error Restart the system If the problem persists contact your Bosch eBike dealer 440 Internal drive unit fault Restart the system If the problem persists contact your Bosch eBike dealer 450 Internal software error Restart the system If the problem persists contact your Bosch eBike dealer 46...

Page 77: ...ature range Switch off the eBike system and allow the battery to either cool down or heat up to the permissible temperature range Restart the system If the problem persists contact your Bosch eBike dealer 606 External battery fault Check the wiring Restart the system If the problem persists con tact your Bosch eBike dealer 610 Battery voltage error Restart the system If the problem persists contac...

Page 78: ...ny components including the drive unit in water or clean them with pressurised water Clean your on board computer using a soft cloth dampened only with water Do not use any detergents Have your eBike system checked by an expert at least once a year including mechanical parts up to dateness of system software The bicycle manufacturer or dealer can also store a distance travelled for the service dat...

Page 79: ...G R E A T B R I T I S H B I K E S ...

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