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Whyte E-150 Operating Instructions And Owner's Manual

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  • Page 2 E-MTB 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...

  • Page 4: Table Of Contents

    Servicing the Whyte Modular Dropout Systems: Disassembly of Modular Rear Dropouts. 7.1.1 Shimano E-Thru 7.1.2 SRAM Maxle 148mm Reassembly of Modular Rear Dropouts. 7.2.1 Shimano E-Thru 7.2.2 SRAM Maxle 148mm Servicing the Whyte Inter Grip Seat Clamp 2019 Page 3...

  • Page 5: Geometry

    Please remember, if you are in any doubt about your ability to safely service or repair your Whyte bike, do not ride it and instead arrange for a professional bicy- cle mechanic at your local Whyte dealer to do the job correctly.

  • Page 6: Preparations For Riding

    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.
  • Page 7 Good Quality Shock Pump. Small Ruler The Front Suspension Fork fitted to your Whyte bike will be pre-set with the standard settings. Before riding, you may need to adjust these setting. First is the Sag setting on the fork. This is to ensure the forks are set-up correctly for your own body weight, allowing the fork to perform as intended.

  • Page 8: Set Up Of Rear Damper

    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 air pressure in the shock absorber determines the spring rate and on a coil Shock, the rating of the spring determines the spring rate.

  • Page 9: Safety

    Always stop riding when making adjustments of any kind to the bicycle! Platform Damping Adjustment. The rear Shock fitted 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”.
  • Page 10 Failure to understand and operate the Bosch components correctly could result in serious injury or death. Designed for the following use: The Whyte eMTB range of bicycles have all been designed, tested and comply with EN-15194:2017 Safety Standard, for typical mountain biking use. 2019...

  • Page 11: Lubrication

    Line Teflon White Lithium Complex grease 5.2: GENERAL WHYTE LUBRICATION For the correct lubrication regime and maintenance of all 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.
  • Page 12 WHYTE Service Manual Item Description M5 x 16mm long Socket-head Capscrew (T-25 Torx®) Collar for M5 Capscrew Hollow Pivot Pin Ø8mm x 31mm long Flanged Nut M12 x 19mm long Flanged Screw M12 x 15mm long Rear Shock Absorber Shock Extender...
  • Page 13 WHYTE Service Manual 6.1.1 To remove only the rear Shock (6) from the frameset IMPORTANT: When removing Rear Shock and/or Seat & Chain stays al- ways brace the rear end and Shock to prevent damage to frame when weight is removed.
  • Page 14 WHYTE Service Manual Figure 4: Disassembly of the Rear Suspension (Third Stage) 6.1.2 To remove the Link (16) & Swinging Arm (14) from the Main Frame (15). Whilst referencing figure 3 & 4, using the 6mm Hex Key, unscrew and remove the M15 x 26mm Flanged alloy Screws (8 and 9) from the front of the H Link (16).
  • Page 15 WHYTE Service Manual 6.1.3 To remove the Chain-stays (14) and Bearings (20) from the Main Frame (15). Whilst referencing figure 5, using the 5mm Hex Key, partially unscrew the M6 x 20mm long Capscrew (10) from the Pivot Pin 80mm long, expanding collet, M15 thread (12).
  • Page 16 WHYTE Service Manual 6.2: STRIPPING AND REASSEMBLING OTHER BEARINGS. (Reference figures 6 & 7) Figure 6: Assembly of Link Item Description ID 15mm, OD 24mm, Width 5mm, bearing (BOLU-WB0025) Shield washer (O.D. 20mm) Shield washer (O.D. 23mm) Various centre-to-centre dimensions Alloy Link Bodies...
  • Page 17 WHYTE Service Manual Figure 7: Assembly of the Seat-stays Item Description ID 15mm, OD 24mm, Width 5mm, bearing (BOLU-WB0025) Middle shield washer (O.D. 20mm) Outer shield washer (O.D. 23mm) Right Seat-stay Left Seat-stay Page 16 2019...
  • Page 18 WHYTE Service Manual Figure 8: Bearing Insertion & Extraction 6802-2RS-MAX (Link or Rear of Seat Stay) Item: Description. M8 Capscrew ISO4162 55 long M8 Washer ISO 7089 M8 Nut ISO 4032 BOLU-WB0025 Bearing BOLU-WB0025 Bearing Tool 1 Mating Component (ie: Link or Seat-Stay)
  • Page 19 WHYTE Service Manual Figure 9: Bearing Insertion & Extraction 6802-2RS-MAX (Above Main Frame Bottom Bracket) Item: Description. M8 Capscrew ISO4762 55 long M12 Nut ISO 4035 I. D. 12 Washer ISO 7089 BOLU-WB0025 Bearing BOLU-WB0025 Bearing Tool 1 Mating Component (ie: Bottom Bracket Yoke)

  • Page 20: Insertion Of Bearings

    WHYTE Service Manual 6.2.1: EXTRACTION OF BEARINGS Tools required: Either 6802-2RS-MAX or 15268-2RS_MAX Bearing press tool 6mm Hex Key 10mm Hex Key 13mm A/F Spanner 18mm A/F Spanner To remove the Bearings (4) from the Link or Rear of the Seat-stay (6). Assemble the parts as shown in figure 8.

  • Page 21: Re-Assembly Of The Rear Suspension

    WHYTE Service Manual Assemble the Shield Washer components (Items 19 in figure 5 or items 2 or 3 in fig- ures 6 & 7). If you have applied enough grease, it should spread from under the Shield Washer or Spacer components as they are positioned. Wipe this excess grease away from around the Shield Washer or Spacer components.
  • Page 22 WHYTE Service Manual 6.3.3: To re-assemble the H Link (16), Shock Extender (7) & Seat-stay (18) onto the Main Frame (15) - Second & Third Stages. IMPORTANT: Prior to reassembly of the Seat-stay (18) to the H Link (16), make sure the Seat tube of the Main Frame (15, not shown for clarity) is inside of the assembly, as in figure 3.

  • Page 23: Servicing The Whyte Modular Dropout Systems

    These Rear Drop-outs are a modular design, that can either be replaced if damaged or converted to one of two different types of through-axle products, ie: Shimano E- Thru or SRAM Maxle 148mm. Contact your local Whyte dealer to purchase either a replacement hanger or a conversion kit.

  • Page 24: Page

    WHYTE Service Manual together with the Rear Derailleur Hanger (2). Also, to remove the Adjuster (4), using the 2mm Hex Key undo the Grub Screw (3) and remove it together with the Adjuster (4). Take care not to loose any of the components.
  • Page 25 WHYTE Service Manual Figure 11: Whyte Dropout Assembly, For Shimano E-Thru Remove the Rear Wheel and using the Torque Wrench, tighten the M4 Countersunk Head Screw (3) to the correct Torque as specified in Section 10.0. Also tighten the M5 Countersunk Head Screw (2). DO NOT OVERTIGHTEN, since the thread of the Screws (2) &...
  • Page 26 WHYTE Service Manual Figure 12: Whyte Dropout Assembly, For SRAM Maxle 148mm Item Description Dropout Spacer (8mm wide) Left Side, for SRAM Maxle 148mm (Gunmetal Col- our) M5 x 16mm long Countersunk Head Screw M4 x 12mm long Countersunk Head Screw Rear Derailleur Hanger, for SRAM Maxle 148mm (Black Colour) M4 x 8 long Grub Screw.
  • Page 27 Plain Sleeve ‘O’ ring Grip Pad Threaded Sleeve Main Frame Seat Post Figure 22 Figure 23 8.0: WHYTE INTER GRIP SEAT CLAMP SERVICE Tools Required: 2x 5mm Hex Keys Small size flat blade screwdriver Torque Wrench (Ranging from 3Nm to...
  • Page 28 WHYTE Service Manual Figure 29 Figure 28 Then push the Plain Sleeve (2) all the way out of the right side of the Main Frame (6). Figures 28 & 29. Remove the Seat Post (7) all the way out of the Main Frame (6).
  • Page 29 WHYTE Service Manual Pad (4) & screw into the Threaded Sleeve (5). Both of the Sleeves (2 & 5) should be nearly flush with the edge of the hole in the Main Frame (6) when the assembly goes tight. If this is not the case, one or other of the four 45°...
  • Page 30 WHYTE Service Manual then feed the outer cable into the chain-stay following the same path as the inner cable. Figure 40: Make sure the inner cable is held tight where it emerges from the chain- stay at the opposite end, otherwise it will be pushed out. Eventually the outer ca- ble will reach the front of the chain-stay.
  • Page 31 WHYTE Service Manual CAUTION: Before installing the seat-post, carefully consult the product manufacturer’s own instructions. Reference figure 42. First prise out the two blank plastic covers near the bottom bracket with a small screwdriver. Reference figure 43. Carefully unscrew the hose from the remote actuator.
  • Page 32 WHYTE Service Manual 10.0: Removal Of Battery Note: Before removing the battery from your Whyte eMTB, please read and understand all rele- vant documentation from Bosch. To ensure that the battery is not being charged, disconnect the charger from the remote battery port.
  • Page 33 WHYTE Service Manual of the bolt. Once the T-25 Torx bolt (1) is removed from the Bottom Cover (2), slide the Bottom Cover (2) off the Down Tube of the frame (3) in the same direction as the axis of the Down Tube (3) so as to completely remove the Bottom Cover (2) from the bicycle.
  • Page 34 10.1: Location Of Bosch Battery On-Off Button. Note: Before making adjustments to the Bosch e-bike system, please read and understand all relevant documentation from Bosch which have been included with your Whyte eMTB. IMPORTANT: For all other Torque settings, refer to the specific manufac- turers information bundled with this manual, or alternatively, refer to the specific manufacturers website for further information.
  • Page 35 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.
  • Page 36 WHYTE Service Manual 11.0: TORQUE SETTINGS Torque explained: If no suitable Torque Wrench is available a Torque of 5 lbf.ft can be ob- tained by applying a force of 5lb, with a Spring Balance, to the end of a spanner, 1 Foot in length.
  • Page 37 WHYTE Service Manual 12.0: OWNER’S NOTES Page 36 2019...
  • Page 38 Performance Line/Cargo Line (§) BOSCH en Original operating instructions...
  • Page 39 0 275 007 XD4 | (12.02.2019) Bosch eBike Systems...
  • Page 40 English – ​ 1 Safety instructions Use only original Bosch batteries that the manufac- turer has approved for your eBike. Using other batter- Read all the safety information and in- ies can lead to injuries and pose a fire hazard. Bosch ac- structions.
  • Page 41 English – 2​ Product description and Product features specifications Individual illustrations in these operating instructions may differ slightly from the actual conditions depending on the equipment of your eBike. Intended use The numbering of the components shown refers to the illus- The drive unit is intended exclusively for driving your eBike trations on the graphics pages at the beginning of the and must not be used for any other purpose.
  • Page 42 English – ​ 3 – The on-board computer is properly inserted in the holder If the eBike is not moved for approx. 10 min and no button is (see on-board computer operating instructions). pressed on the on-board computer, the eBike system switches off automatically in order to save energy.
  • Page 43 English – 4​ Switching the push assistance on/off Interaction between the eBike system and gear- shifting The push assistance aids you when pushing your eBike. The speed in this function depends on the selected gear and can The gear-shifting should be used with an eBike drive in the reach a maximum of 6 km/h.
  • Page 44 English – ​ 5 Maintenance and servicing Maintenance and cleaning 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 re- placed with bulbs of the same voltage.
  • Page 46 PowerPack 300|400|500/PowerTube 400|500|625 BBS245 | BBR245 | BBS265 | BBR265 | BBS275 | BBR275 | BBP280 | BBP281 | BBP282 | BBP283 | BBP290 | BBP291 en Original operating instructions...
  • Page 47 (13) (12) (11) (13) (12) 0 275 007 XPX | (20.12.2018) Bosch eBike Systems...
  • Page 48 (12) (13) (16) (14) (14) (15) (11) Bosch eBike Systems 0 275 007 XPX | (20.12.2018)
  • Page 49 7 ° (10) (10) 0 275 007 XPX | (20.12.2018) Bosch eBike Systems...
  • Page 50 (14) (15) (15) (14) (15) Bosch eBike Systems 0 275 007 XPX | (20.12.2018)
  • Page 51 0 275 007 XPX | (20.12.2018) Bosch eBike Systems...
  • Page 52 English – ​ 1 Safety instructions ence any adverse effects. The fumes may irritate the respiratory system. Read all the safety and Only charge the battery using original Bosch chargers. general instructions. Fail- When using chargers that are not made by Bosch, the risk ure to observe the safety of fire cannot be excluded.
  • Page 53 English – 2​ (4) On/off button (11) Charger (5) Key for the battery lock (12) Socket for charging connector (6) Battery lock (13) Charging socket cover (7) Upper standard battery holder (14) PowerTube battery safety restraint (8) Standard battery (15) PowerTube battery (9) Lower standard battery holder (16) PowerTube battery safety hook (10) Cover (supplied only on eBikes with two battery...
  • Page 54 English – ​ 3 Charging the battery Charging process for two batteries If two batteries are fitted to an eBike, both batteries can be Use only the charger included with your eBike or an charged using the uncovered connection. To begin with, identical original Bosch charger.
  • Page 55 English – 4​ To remove the rack-mounted battery (2), switch it off and To switch off the battery, press the on/off button (4) again. open the lock using the key (5). Pull the battery out of the The LEDs on the indicator (3) will go out. This will also holder (1).
  • Page 56 English – ​ 5 Disposal above 60 °C. To ensure that the service life is as long as pos- sible, storage at approx. 20 °C (room temperature) is re- Batteries, accessories and packaging should be commended. recycled in an environmentally friendly manner. Make sure that the maximum storage temperature is not ex- Do not dispose of batteries along with household waste.
  • Page 57 English – 6​ 0 275 007 XPX | (20.12.2018) Bosch eBike Systems...
  • Page 58 Charger BCS220 | BCS230 | BCS250 en Original operating instructions...
  • Page 59 Standard Charger Fast Charger eBike Battery Charger 36-4/230 Standard Charger BCS220 0 275 007 907 Input: 230V 50Hz 1.5A Li-Ion Output: 36V Use ONLY with BOSCH Li-Ion batteries Made in PRC Robert Bosch GmbH, Reutlingen eBike Battery Charger 36-6/230 Fast Charger BCS250 0 275 007 918 Input: 230V 50Hz 2.15A...
  • Page 60 Compact Charger BCS230 Bosch eBike Systems 0 275 007 XCX | (24.04.2018)
  • Page 61 (11) (10) 0 275 007 XCX | (24.04.2018) Bosch eBike Systems...
  • Page 62 (11) Bosch eBike Systems 0 275 007 XCX | (24.04.2018)
  • Page 63 0 275 007 XCX | (24.04.2018) Bosch eBike Systems...
  • Page 64 English – ​ 1 Safety instructions Read and observe the safety warnings and directions contained in all the eBike system operating instruc- Read all the safety and tions and in the operating instructions of your eBike. general instructions. Fail- A sticker in English is adhered to the bottom of the char- ure to observe the safety ger (marked (4) in the diagram on the graphics page).
  • Page 65 English – 2​ Technical data Charger Standard Charger Compact Charger Fast Charger (36–4/230) (36–2/100-230) (36–6/230) Product code BCS220 BCS230 BCS250 Rated voltage 207...264 90...264 207...264 Frequency 47...63 47...63 47...63 Battery charging voltage Charging current (max.) 6  Charging time – PowerPack 300, approx. –...
  • Page 66 English – ​ 3 The state of charge is displayed by the battery charge indic- Cause Corrective measures ator (9) on the battery and by the bars on the on-board com- Socket outlet, cable or char- Check the mains voltage, puter.
  • Page 67 English – 4​ 0 275 007 XCX | (24.04.2018) Bosch eBike Systems...
  • Page 68 Purion BUI210 | BUI215 en Original operating instructions...
  • Page 69 (8) (9) L A L A L K L K L K L K L K K K L K K L K L A L W W A W W W W A W W A A 1 270 020 XBP | (11.02.2019) Bosch eBike Systems...
  • Page 70 L A A L K L K K L K L K L K K K L K K L K L A L W W W W A W W A A W W A (10) Bosch eBike Systems 1 270 020 XBP | (11.02.2019)
  • Page 71 1 270 020 XBP | (11.02.2019) Bosch eBike Systems...
  • Page 72 English – ​ 1 Safety instructions (d) Total distance indicator TOTAL (e) Range indicator RANGE Read all the safety information and in- (f) Service indicator structions. Failure to observe the safety in- (g) Battery charge indicator formation and follow instructions may result in electric shock, fire and/or serious injury.
  • Page 73 English – 2​ Operation Energy supply of the on-board computer The on-board computer is supplied with voltage by two CR2016 button cells. Symbols and their Meaning Changing the batteries (see figure A) Symbol Explanation If the on-board computer shows LOW BAT on the display, Short button press (less than 1 second) remove the on-board computer from the handlebars by un- screwing the fastening screw (3) of the on-board computer.
  • Page 74 English – ​ 3 – ECO: Effective assistance with maximum efficiency, for maximum range – TOUR: Steady assistance, long range for touring – SPORT/eMTB: SPORT: Powerful assistance, for mountain biking and cycling in urban traffic eMTB: Optimum assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dy- namics and top performance (eMTB only available in combination with the drive units BDU250P CX, BDU365,...
  • Page 75 English – 4​ Displays and configurations of the Action Buttons Duration Switch on on-board computer on-board computer Switch off on-board computer Battery charge indicator Increase assistance The battery charge indicator (g) displays the eBike battery's Decrease assistance – state of charge. The state of charge of the eBike battery can Display TRIP, TOTAL, RANGE, –...
  • Page 76 English – ​ 5 Error code display will always be able to do so without assistance from the drive. Before undertaking any other journeys, the eBike The eBike system's components are continuously and auto- should be checked. matically monitored. If an error is detected, the correspond- Have all repairs performed only by an authorised bike ing error code is displayed on the on-board computer.
  • Page 77 English – 6​ Code Cause Corrective measures Temperature error The eBike is outside of the permissible temperature range. Switch off the eBike system and allow the drive unit to either cool down or heat up to the permissible temperature range. Restart the system. If the problem persists, contact your Bosch eBike dealer.
  • Page 78 English – ​ 7 Code Cause Corrective measures situation, e.g. riding solely on the rear wheel Fault in the wire to the rear wheel speed Contact your Bosch eBike dealer. sensor Implausible signals from the rear wheel Restart the system and carry out a test ride lasting at least two 833 to 835 speed sensor minutes.
  • Page 79 G R E A T B R I T I S H B I K E S...

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E-180

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