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SMART RL22 Repair Instructions

For replacing the rear belt pulley

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RL22 - Repair instructions for replacing the rear belt pulley
Version 1.0, last revised 03/2016
Number of work units required (1WU = 5 minutes = EUR 6.00 net):
A. Removing the belt guard (only on models with belt guard)
B. Reducing the belt tension
C. Removing the belt guide
D. Removing the rear wheel
E. Removing the belt pulley
F. Installing the belt pulley
G. Installing the rear wheel
H. Aligning the mudguard stays
I. Aligning the belt
J. Adjusting the belt tension
K. Installing the belt guide
L. Adjusting the shift mechanism
M. Aligning the brake caliper
N. Installing the belt guard (only on models with belt guard)
Required tools/material
2 x box wrench/open end wrench, size 10
Torque driver 1-5Nm
Torque Vario 3-15Nm
Torque Vario 22 Nm, 35 Nm
Eco Tension Tester
Grease
Open end wrench, size 15
Allen wrench, size 2.5, 5, 6
Assembly stand
Snap ring pliers
T20, T25 Torx wrench
T25 angled Torx wrench
Transport lock
Warning
Always remove the battery from the frame before performing repair and maintenance work on electrical components and
on the rear wheel.
The basic requirement for proper and low-wear operation of the belt drive is a correctly adjusted belt tension.
 If the tension of the belt is too low and the load too high, the belt can skip on the teeth of the rear belt pulley. Under
certain circumstances this can cause damage to the carbon fiber elements, resulting in irreparable damage to the belt. If
the belt has skipped, it should be replaced preemptively to minimize the risk of the belt breaking during operation.
 If the tension of the belt is too high, bearings and seals inside the rear wheel hub could be damaged. Also, the system
will operate with noticeable resistance and will wear out more quickly.
The carbon fibers can withstand high tensile forces, but they are sensitive to bending loads, shearing forces, nicks and
impacts. Even though the carbon fibers in the belt are sheathed, the utmost care is necessary when handling the Carbon
Drive. All the points listed below can cause damage to the carbon fibers inside the drive belt. A drive belt which has been
damaged in this way could snap suddenly and unexpectedly under load while cycling. On no account should a damaged
drive belt be reused.
11
Possible vehicle damage
Item number (Retailworld)
-
AZK00889
AZK00886
-
AZK00880
-
-
-
AZK00893
-
-
-
AZK00879
Tip,
info
1/16

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Summary of Contents for SMART RL22

  • Page 1 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 Number of work units required (1WU = 5 minutes = EUR 6.00 net): A. Removing the belt guard (only on models with belt guard) B. Reducing the belt tension C.
  • Page 2 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 The following movements must be avoided at all costs when handling the drive belt: Kinking it Twisting it Bending it against its curvature Turning it inside out...
  • Page 3 To rule out the possibility of the belt skipping on the rear belt pulley, a guide is installed on the dropout of your smart ebike. This ensures that the belt always remains meshed with the belt pulley. The guide can be moved in the slot in the dropout after slackening the mounting bolt.
  • Page 4: Removing The Rear Wheel

    RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 B. Reducing the belt tension In order to allow the belt to be removed from the belt pulleys without tension, the distance between the spindle of the bottom bracket and the rear axle must be reduced.
  • Page 5 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 9. Separate the connection between the shift cable and the rear wheel hub on the right chain stay by pressing the tab on the locating sleeve and pulling the sleeve off the threaded element.
  • Page 6 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 14. Carefully press the belt off the rear belt pulley first, and then off the front belt pulley. Alternatively, push the lower span of the belt carefully towards the ebike so that it runs off the front belt pulley when the crank is turned backwards.
  • Page 7 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 E. Removing the belt pulley 17. Slightly grease the belt pulley mount. 18. Take off the spacer ring and the old belt pulley. On older versions, the spacer ring may also be installed behind the belt pulley.
  • Page 8: Installing The Rear Wheel

    RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 G. Installing the rear wheel 24. Remove the transport lock from the rear brake caliper. Hang the belt behind the mounting of the belt guide while you are inserting the rear wheel into the dropouts.
  • Page 9 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 27. Hang the belt beside the rear belt pulley at first, and then fit it onto the front belt pulley. 28. Carefully guide the belt onto the rear belt pulley.
  • Page 10 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 32. The mudguard stays can be adjusted to fit the wheel by pulling them out or pushing them in. 33. Tighten the clamping bolts to a torque of 1 Nm.
  • Page 11: Aligning The Belt

    RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 I. Aligning the belt 34. Turn the crank forwards and backwards 10 - 15 times and watch the line that the belt follows. The belt should only slightly touch the side stop (flange) of the rear belt pulley or it should have a gap of no more than approx.
  • Page 12 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 38. The correct belt tension is achieved when the belt just touches the top of the chain stay with one tooth. 39. Since the tension can vary slightly along the length of the belt, this procedure should be performed again at intervals along the belt.
  • Page 13 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 K. Installing the belt guide 43. Install the belt guide in the slot of the right dropout using a size 5 Allen wrench. Align it at a distance of 1 – 1.5 mm from the back of the belt and tighten the bolt to a torque of 6 Nm.
  • Page 14 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 47. It must not be possible to pull the shift cable further out of the gear hub by pulling on the plastic locating sleeve.  If the shift cable has too much play, turn the twist grip to 1 gear.
  • Page 15 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 54. Operate the brake lever several times with the wheel turning. Then check whether the brake pads on both sides are pulled away from the brake disc and are positioned parallel to it.
  • Page 16 RL22 - Repair instructions for replacing the rear belt pulley Version 1.0, last revised 03/2016 59. Tighten the threaded connection on the battery nest with a T25 Torx wrench and a torque of 2 Nm. 16/16...