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BionX Smart Repair Instructions

For changing the frame
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RL39 - Repair instructions for changing the frame
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 cable outlets
F.
Removing the right crank
G.
Removing the left crank
H.
Removing the kickstand plate
I.
Removing the inner bearing
J.
Removing the battery nest
K.
Removing the rear mudguard
L.
Removing the right brake line
M.
Removing the rear brake caliper
N.
Removing the dropouts
O.
Removing the front wheel
P.
Removing the front mudguard
Q.
Removing the front brake caliper
R.
Removing the stem trim
S.
Removing the stem
T.
Removing the headset
U.
Removing the saddle clamp
V.
Installing the saddle clamp
W.
Installing the fork
X.
Installing the stem
Y.
Installing the front brake caliper
Z.
Installing the front mudguard
AA. Installing the front wheel
BB. Installing the dropouts
CC. Installing the rear mudguard
DD. Installing the battery nest
EE. Installing the inner bearing
FF. Installing the left crank
GG. Installing the right crank
HH. Installing the shift sleeve
II.
Installing the right brake line
JJ. Installing the cable outlets
KK. Installing the rear wheel
LL. Aligning the belt
MM. Adjusting the belt tension
NN. Installing the belt guide
OO. Adjusting the headset play
PP. Aligning the front light
QQ. Installing the stem trim
RR. Installing the shift cable
SS. Adjusting the shift mechanism
TT. Preparing the brake caliper
UU. Preparing the brake lever
VV. Filling/ bleeding the brake
WW. Checking the pressure point
XX. Installing the rear brake caliper
YY. Aligning the brake caliper
ZZ. Installing the kickstand plate
AAA. Installing the belt guard (only on models with belt guard)
BBB. Updating the drive system
46
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Summary of Contents for BionX Smart

  • Page 1 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 Number of work units required (1WU = 5 minutes = EUR 6.00 net): Removing the belt guard (only on models with belt guard) Reducing the belt tension Removing the belt guide Removing the rear wheel Removing the cable outlets...
  • Page 2 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 Required tools/material Item number (Retailworld) 2 x cable connector 3M SMZ013-11 2 x box wrench/open end wrench, size 10 BionX Interface Box (BIB) AZK00840 Brake cleaner Torque driver 1-5Nm AZK00889 Torque Vario 3-15Nm AZK00886...
  • Page 3 RL39 - Repair instructions for changing the frame 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 Lashing or tying it together with a cable tie or cord Using it as a wrench Installing the drive belt under tension with a lever...
  • Page 4 When filling the disc brake system on your smart ebike, you should only use the mineral oil offered by the brake manufacturer (“Magura Royal Blood”). Oils from other manufacturers and DOT brake fluid could cause damage to the seals and lead to failure of the brakes.
  • Page 5 RL39 - Repair instructions for changing the frame 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. To do this, use the horizontally adjustable dropouts of the ebike.
  • Page 6 RL39 - Repair instructions for changing the frame 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 7 RL39 - Repair instructions for changing the frame 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 8 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 E. Removing the cable outlets 17. Undo the bolts of the cable outlet on the right side of the downtube using a T25 Torx wrench and detach the cable outlet. 18.
  • Page 9 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 21. Remove the crank by turning the puller screw of the crank remover clockwise. Always observe the notes on handling the belt. 22. Take the crank off the axle. G.
  • Page 10 The smart ebike has an inner bearing which can be adjusted in the axial direction by means of spacer rings. This allows the line of the belt to be corrected.
  • Page 11 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 30. Fit the inner bearing tool on the internal teeth on the left of the inner bearing and detach the plastic shell. When doing so, hold the inner bearing tool with your other hand so that it does not accidentally slip out of the teeth.
  • Page 12 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 J. Removing the battery nest 34. Carefully unplug the data cable from the jack underneath the stem assembly. 35. Pull out the light cable connectors (3M Scotchlok 36.

  • Page 13: Removing The Rear Mudguard

    RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 42. Grip the rear data cable in the bottom bracket and pull and feed it out of the frame. 43. Undo the bolts of the battery nest using a T30 angled Torx wrench and remove the collared washers.
  • Page 14 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 48. Take the belt off the frame. 49. Undo the two bolts on the frame with a T25 Torx wrench and remove the mudguard connection from the frame. L.
  • Page 15 A restrainer on the fork of the smart ebike prevents the front wheel from falling out accidentally when the quick- release lever is opened. To remove the wheel, also slacken the nut on the opposite side from the quick-release lever.

  • Page 16: Removing The Front Mudguard

    RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 55. Open the quick-release lever and remove the front wheel from the fork. 56. Push the transport lock between the brake pads. P. Removing the front mudguard 57.
  • Page 17 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 Q. Removing the front brake caliper 59. Pull the brake line guide off the brake line. (Also when converting from a rigid fork to a suspension fork!) CAUTION: When replacing a suspension fork: Cut the cable tie on the fork bridge using side cutting pliers.
  • Page 18 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 65. Carefully push the control console cradle approx. 1 cm upwards out of the housing by pressing carefully from below between the cable jacks while simultaneously pulling up on the control console cradle. 66.
  • Page 19 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 69. Undo the threaded connection of the A-head cap using a size 5 Allen wrench and remove the A-head cap. In the next step, the fork can fall down out of the head tube. Secure the fork with a tensioning strap or a cable tie to prevent it from falling.

  • Page 20: Removing The Fork

    RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 71. Pull the handlebar/stem assembly upwards off the steerer tube. Make sure that you do not damage the light cable. Fasten the handlebar/stem assembly to the frame. For this, use a tensioning strap for example.
  • Page 21 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 T. Removing the headset 77. Remove the sealing ring from the headset. 78. Remove the clamping ring from the headset. 79. Remove the bearing from the headset. 80.
  • Page 22 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 U. Removing the saddle clamp 82. Take the frame out of the assembly stand and undo the bolt of the saddle clamp with a size 5 Allen wrench. Pull the saddle clamp off the seat tube.

  • Page 23: Installing The Stem

    RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 86. Push the second bearing onto the steerer tube with the fork seat ring (upper headset shell). The chamfered side of the bearing inner race faces downwards; the chamfered side of the bearing outer race faces upwards.

  • Page 24: Installing The Front Brake Caliper

    RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 92. Fit the A-head cap and tighten it initially only enough to hold the fork and the headset parts in place. 93. (e.g. when replacing the frame: Insert the light cable into the left cable outlet in the downtube and feed it through as far as the opening under the bottom bracket shell.
  • Page 25 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 95. Fit the brake caliper onto the mudguard bracket and onto the brake mounting of the fork. Make sure that the brake disc is correctly seated between the brake pads.
  • Page 26 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 99. Screw the brake pad retaining bolt into the brake caliper. Make sure that it passes through the “ears” of the brake pad carrier. Tighten the brake pad retaining bolt to a torque of 2.5 Nm.
  • Page 27 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 105. Suspension fork: Hook the metal plate in the mudguard bracket. Place the plastic plate over the holes and bolt the mudguard onto the mudguard bracket using a cross head screwdriver.
  • Page 28 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 A T20 Torx wrench can be used to slacken the clamping bolts on the mudguard stays. The mudguard stays can be adjusted to fit the wheel by pulling them out or pushing them in.
  • Page 29 When closed, the quick-release lever must be at right angles to the axle so that the self-locking effect of the cam functions correctly. Incorrectly closed quick-release clamps can open while cycling. The axle on the front wheel of the smart ebike is fitted with a quick-release system for rapid assembly and disassembly. The quick-release clamp basically consists of two elements: ...
  • Page 30 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 CC. Installing the rear mudguard 120. Install the mudguard connection on the frame and tighten the two bolts to a torque of 2 Nm using a T25 Torx wrench. Only use genuine bolts or, if reinstalling used bolts, apply a drop of thread lock (medium strength, e.g.
  • Page 31 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 124. First loosely screw the mudguard stays to the dropouts with T30 Torx wrench. 125. Attach the mudguard stay brackets to the mudguard and hook the mudguard stays into the mudguard.
  • Page 32 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 127. Tighten the bolts attaching the mudguard to the dropouts with a T30 Torx wrench to a torque of 4 Nm. A T20 Torx wrench can be used to slacken the clamping bolts on the mudguard stays.
  • Page 33 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 132. Feed the welding rod through the left opening in the rear stay to the bottom bracket. 133. Fasten the power cable to the welding rod using adhesive tape and pull and feed it through the frame.
  • Page 34 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 137. Please note the color coding of the cables. BionX battery front rear light light 0725-12-1 138. Fit the two 3M Scotchlok connectors as follows:  Connect the black light cable from the battery nest to the two black/white light cables of the lights.
  • Page 35 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 142. If necessary, push the correct number of spacer rings onto the right bearing shell, if these were installed on this frame before. Screw in the right bearing shell counterclockwise using the inner bearing tool and tighten it to a torque of 25 Nm.
  • Page 36 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 The seals for the left and right bearing shells are different. The seal carrier for the left bearing shell is 16.6 mm long; the seal carrier for the right side is 14.0 mm long.
  • Page 37 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 GG. Installing the right crank 148. Grease the square of the inner bearing axle and fit the crank. An inexact tightening torque for the right crank bolt can alter the line of the belt. 149.
  • Page 38 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 Installing the shift sleeve 152. Attach end caps to the new shift sleeve and push it through the right cable outlet towards the bottom bracket. 153. Feed the shift sleeve under the bottom bracket into the downtube of the frame. 154.
  • Page 39 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 Proceed carefully when pushing the brake line through the frame so as not to damage the cable harness. 158. Clamp the brake line in the groove of the assembly tool and fix it in place with a second transport lock and clamping pliers (or a vise).
  • Page 40 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 164. Install the cable outlets on the right side of the downtube and on the right rear stay. Tighten the bolt with a T25 Torx wrench and a torque of 2 Nm. 165.
  • Page 41 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 168. Guide the rear wheel into the dropouts. Take care not to crush the belt. Also make sure that the anti-twist lock of the tooth lock washer is correctly aligned relative to the dropout.
  • Page 42 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 172. Feed the cables through the cable guide and connect first the power cable and then the data cable to the motor. LL. Aligning the belt 173. Turn the crank forwards and backwards 10 - 15 times and watch the line that the belt follows.
  • Page 43 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 177. The correct belt tension is achieved when the belt just touches the top of the chain stay with one tooth. 178. Since the tension can vary slightly along the length of the belt, this procedure should be performed again at intervals along the belt.
  • Page 44 6 Nm. OO. Adjusting the headset play The bearing of the fork in the frame (headset) of the smart ebike must rotate easily and without play. 183. Stand the ebike on the ground and place your fingers around the gap between the head tube and the fork crown.
  • Page 45 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 187. Now tighten the stem clamping bolts alternately and in small increments to a torque of 10 Nm. PP. Aligning the front light 188. Fit the control console on the control console cradle and connect the data cable. 189.
  • Page 46 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 195. Carefully push the control console cradle all the way into the stem assembly. 196. Tighten the bolt in the control console cradle with a T20 Torx wrench and a torque of 2 Nm.
  • Page 47 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 RR. Installing the shift cable 199. Feed the new shift cable through the twist grip. 200. Fit the adjusting nut on the shift cable. 201. Feed the shift cable into the shift sleeve until the nipple of the shift cable disappears entirely in the twist grip.
  • Page 48 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 206. Feed the shift cable through the plastic sleeve. Pull the shift cable taut. When the shift cable cannot be pulled any further out of the shift sleeve, clamp it by tightening the grub screw with a size 2.5 Allen wrench and a torque of 3 - 4 Nm.
  • Page 49 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 212. 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 1st gear. Reduce the play in the shift cable by turning the adjusting nut on the twist grip.
  • Page 50 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 217. Insert the thick end of the transport lock into the brake caliper between the slave pistons and secure it with an elastic band. 218. (only for front brake caliper) Align the brake caliper so that the brake caliper retaining bolts are lined up vertically, exactly one above the other.
  • Page 51 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 VV. Filling/ bleeding the brake Never pull the brake lever while the brake system is open. 221. (only front brake caliper) Remove the upper brake caliper retaining bolt using a size 5 Allen wrench. 222.
  • Page 52 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 228. Draw the mineral oil back again with the lower filling syringe. Make sure that there is always sufficient mineral oil in the bleed kit bottle on the brake lever so that no air is drawn into the brake system from there.
  • Page 53 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 237. Realign the brake lever correctly and then tighten the lower brake lever retaining nut with the T25 Torx wrench and a torque of 3 Nm. Checking the pressure point 238.
  • Page 54 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 244. Press the brake pads in the brake caliper apart with the aid of the transport lock and fit the brake caliper on the brake mounting of the rear stay. Make sure that the brake disc is correctly seated between the brake pads.
  • Page 55 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 249. Tighten the brake caliper retaining bolts alternately and in stages to a torque of 6 Nm. 250. Release the brake lever and check the alignment of the brake caliper with the brake disc.
  • Page 56 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 AAA. Installing the belt guard (only on models with belt guard) Make sure that you do not trap any cables from the bottom bracket shell when installing the kickstand plate. Only use genuine bolts or, if reinstalling used bolts, apply a drop of thread lock (medium strength, e.g.
  • Page 57 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 BBB. Updating the drive system 258. Carefully unplug the data cable from the jack underneath the stem assembly. 259. Connect the BIB to the data cable and to the jack underneath the stem assembly. Plug the USB connector into the computer.
  • Page 58 RL39 - Repair instructions for changing the frame Version 1.0, last revised 03/2016 263. Take care not to touch any of the connecting cables during the update process as this could accidentally interrupt the data connection. Click on “Yes, proceed with the update”...