Table of Contents
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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE FOR LATER REFERENCE
TRANSLATION OF THE ORIGINAL
EN
OPERATING INSTRUCTIONS
ELECTRIC BICYCLES
Comfort, Escaro Comp 8, Escaro Cross, EscaroPro,
Quadriga Cityhopper, Quadriga CX, Quadriga Cross,
Quadriga Plus, Quadriga
KB065-VAKxxx, KB065-VBKxxx, KB065-VCKxxx, KB066-VAFxxx, KB066-VBFxxx, KB066-VCFxxx,
KB068.VAFxxx, KB068-VARxxx, KB069-VAFxxx, KB070-VAKxxx, KB070-VBKxxx, KB076-VAFxxx,
877-00136 • 1.0 • 13 September 2018
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Summary of Contents for Kettler Comfort
- Page 1 KEEP SAFE FOR LATER REFERENCE TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS ELECTRIC BICYCLES Comfort, Escaro Comp 8, Escaro Cross, EscaroPro, Quadriga Cityhopper, Quadriga CX, Quadriga Cross, Quadriga Plus, Quadriga KB065-VAKxxx, KB065-VBKxxx, KB065-VCKxxx, KB066-VAFxxx, KB066-VBFxxx, KB066-VCFxxx, KB068.VAFxxx, KB068-VARxxx, KB069-VAFxxx, KB070-VAKxxx, KB070-VBKxxx, KB076-VAFxxx,...
- Page 2 Copyright © ZEG Zweirad-Einkaufs-Genossenschaft eG Distribution or reproduction 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.
- Page 3 Data sheet Surname, first name of the purchaser: Date of purchase: Model: Frame number: Type number: Unladen weight (kg): Tyre size: Recommended tyre pressure (bar)*: front: rear: Wheel circumference (mm): Company stamp and signature: *After a tyre change, refer to the tyre markings for the permitted tyre pressures and make sure that they are observed.
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Page 4: Table Of Contents
Table of contents Table of contents About these instructions Manufacturer Laws, standards and directives Other valid documents Subject to change Language For your safety 1.6.1 Instruction, training and customer service 1.6.2 Basic safety notes 1.6.3 Warnings 1.6.4 Safety markings For your information 1.7.1 Instructions for actions 1.7.2... - Page 5 Table of contents 3.6.1 Battery 3.6.1.1 Operating and charge status indicator 3.6.2 Operating element with display 3.6.2.1 Level of assistance 3.6.2.2 Current speed 3.6.2.3 System message Technical data Transportation, storage and assembly Transportation 5.1.1 Using the transport securing system Storing 5.2.1 Break in operation 5.2.1.1...
- Page 6 Table of contents 6.3.2 Adjusting the grip distance 6.3.2.1 Adjusting the grip distance on a Magura brake lever Retracting brake linings Operation Before each ride Check list before each ride Using the kickstand Battery 7.4.1 Integrated battery 7.4.1.1 Removing the integrated battery 7.4.1.2 Inserting the integrated battery 7.4.2...
- Page 7 Table of contents 8.1.2.7 Cleaning the battery 8.1.2.8 Cleaning the drive unit 8.1.2.9 Cleaning the display 8.1.2.10 Cleaning the brake 8.1.3 Servicing 8.1.3.1 Servicing the frame 8.1.3.2 Servicing the stem 8.1.3.3 Servicing the fork 8.1.3.4 Servicing the drive elements 8.1.3.5 Servicing the pedal 8.1.3.6 Servicing the chain...
- Page 8 Table of contents Recycling and disposal Appendix 10.1 EC declaration of conformity 10.2 Parts list 10.3 Table of figures 10.4 Subject index 877-00136_1.0_17.09.2018...
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Page 9: About These Instructions
Information for specialist staff does not require non-professionals to take any action. Manufacturer The manufacturer of the bicycle is: KETTLER Alu-Rad GmbH Longericher Straße 2 50739 Köln, Germany Tel.: +49 6805 6008-0... -
Page 10: Laws, Standards And Directives
About these instructions Laws, standards and directives These operating instructions comply with the essential requirements from: • the Machinery Directive 2006/42/EC, • Electromagnetic Compatibility Directive 2014/30/EU, • EN ISO 12100:2010 Safety of machinery – General principles of design – Risk assessment and reduction, •... -
Page 11: Subject To Change
Any significant changes are included in a new issue of the operating instructions. You will find any modifications to these operating instructions at: www.kettler-alu-rad.de/de/de/index/service/anleitung Language The original operating instructions are written in German. A translation is not valid without the original operating instructions. -
Page 12: For Your Safety
If you are unable to contact your specialist dealer, you will find other specialist dealers to attend to your customer service needs on www.kettler-alu-rad.de. The specialist dealer authorised to perform repairs and maintenance work receives regular training. -
Page 13: Basic Safety Notes
About these instructions 1.6.2 Basic safety notes These operating instructions have a chapter with general safety notes. You can distinguish this chapter as it has a grey background. 1.6.3 Warnings Hazardous situations and actions are marked with warnings. The warnings in these operating instructions are shown as follows: Type and source of the danger SIGNAL WORD... -
Page 14: Safety Markings
About these instructions 1.6.4 Safety markings The following safety markings are used on the bicycle's type plates: General warning Adhere to the instructions for use Table 2: Safety markings on the product For your information 1.7.1 Instructions for actions Instructions for actions are structured in accordance with the following pattern: ... -
Page 15: Information On The Type Plate
About these instructions 1.7.2 Information on the type plate Alongside the warnings, the type plates of the products also contain other important information on the bicycle: only suitable for the road, no off-road riding or jumps suitable for roads, off-road riding and jumps of up to 15 cm suitable for rough off-road riding and jumps of up to 61 cm... -
Page 16: Language Conventions
About these instructions Read the instructions Separate collection of electrical and electronic devices Separate collection of batteries Must not be thrown into fire (burning prohibited) Must not be thrown into water (immersed) Device of protection class II Only suitable for use indoors Fuse (device fuse) EU conformity Recyclable material... - Page 17 About these instructions Alternative version explains the various variants of components if they differ in use. The following terms are used for better legibility: Term Meaning Operating Original operating instructions instructions or translation of the original operating instructions Bicycle Electric motor driven cycle Motor Drive motor Table 6:...
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Page 18: Type Plate
About these instructions Type plate The type plate is situated on the frame. The type plate features the following information: KETTLER Alu-Rad GmbH Longericher Str. 2 50739 Köln, Germany Typ: 19-16-0001 EPAC nach EN 15194 0,25 kW / 25 km/h... -
Page 19: Identifying
Identification number of the operating instructions 1.9.2 Bicycle These KETTLER operating instructions refer to the model year 2019. The production period is from August 2018 to July 2019. They are issued in August 2018. The operating instructions are a component part of the... - Page 20 About these instructions Type number Model Bicycle type KU121-VAFD46 2° E Compact City and trekking bicycle KU159-VAKD50 2° E Comp Street City and trekking bicycle KU159-VAKD55 2° E Comp Street City and trekking bicycle KU159-VAKD60 2° E Comp Street City and trekking bicycle KU159-VAKT45 2°...
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Page 21: Safety
Safety Safety Requirements for the rider If there are no legal requirements for riders of electrically power-assisted cycles, we recommend that the rider should be a minimum 14 years of age and have experience with muscle-powered bicycles. The physical and mental abilities of the rider must be sufficient for riding on public roads. -
Page 22: Proper Use
Safety Proper use The bicycle is designed to support a maximum speed of 25 km/h. The bicycle may only be used in a perfect, fully functional condition. National requirements may apply to the bicycle which differ from the standard equipment. For riding on public roads, some special regulations apply in relation to the driving light, reflectors and other components. -
Page 23: Improper Use
City and trekking bicycle City and trekking bicycles are not sports bicycles. If used for sports, the rider can expect reduced riding stability and diminished comfort. Non-permitted areas of use Never drive off-road or perform jumps. Never drive off-road or perform jumps over 15 cm. -
Page 24: Duty To Take Care
Safety Duty to take care The safety of the bicycle can only be assured if all the necessary measures are taken. 2.6.1 Rider The rider: • receives instruction before the first ride. They can clarify any questions relating to the operating instructions with the operator or specialist dealer •... -
Page 25: Description Overview
Description Description Overview Figure 2: Bicycle viewed from the right, 2° E Beltdrive used as example Front wheel Fork Handlebars Stem Frame with integrated display Seat post Saddle Reflector Rear wheel Chain Frame number and type plate 877-00136_1.0_17.09.2018... - Page 26 Description Handlebars Figure 3: Detailed view of bicycle from rider position, example Rear brake lever Front brake lever Bell Integrated display 877-00136_1.0_17.09.2018...
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Page 27: Wheel And Fork
Description Wheel and fork Figure 4: Components of the wheel – example showing front wheel Tyre Suspension fork head with setting wheel Fork Spoke Quick release Valve Fork end of the suspension fork 3.3.1 Valve Each wheel has a valve. It is used to fill the tyre with air. - Page 28 Description Dunlop valve The rider can easily exchange the valve and quickly release the air. The air pressure cannot be measured with this valve. Presta valve The presta valve requires a smaller hole in the rim, which is why it is especially suitable for the narrow rims of racing bicycles.
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Page 29: Brake System
Description Brake system The bicycle is equipped with a disc brake. Figure 5: Rim brake components with details – example: Magura HS22 Rear wheel rim brake Brake booster Brake lining Handlebars with brake levers Front wheel rim brake The rim brake stops the wheel moving when the rider pulls the brake lever, causing two brake linings, positioned opposite one another, to be pressed onto the rims. - Page 30 Description The hydraulic rim brake features a locking lever Figure 6: Rim brake locking lever, closed (1) and open (2) The rim brake locking lever is not marked with any lettering. Only a specialist dealer may set the rim brake locking lever.
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Page 31: Electric Drive System
Description Electric drive system Drive system The bicycle is driven by muscle power via the chain drive. The force which is applied by pedalling in the direction of travel, drives the front chain wheel. The chain transmits the force onto the rear chain wheel and then onto the rear wheel. - Page 32 Description Figure 8: Diagram of electric drive system Operating element with display Integrated battery Motor • a charger which is designed for this battery. As soon as the required muscle power from the rider pedalling passes a certain level, the motor is activated gently and assists the pedalling motion of the rider.
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Page 33: Battery
Description 3.6.1 Battery The lithium ion battery has an internal electronic protection circuit. It is matched to the charger and the bicycle. The battery temperature is monitored at all times. The battery is safeguarded against deep discharge, overcharging, overheating and short circuit. -
Page 34: Operating And Charge Status Indicator
Description The bicycle has an integrated battery. Figure 9: Integrated battery details Battery housing On-Off switch Operating and charge status indicator Connection cover for charger plug Down tube Battery lock 3.6.1.1 Operating and charge status indicator The five green LEDs of the operating and charge status indicator indicate the charge status of the battery when the battery is switched on. -
Page 35: Operating Element With Display
Description 3.6.2 Operating element with display The operating element with display controls the drive system and shows journey data. The bicycle's battery supplies the operating element with display with energy when a sufficiently charged battery is inserted on the bicycle, and the drive system is switched on. -
Page 36: Level Of Assistance
Description 3.6.2.1 Level of assistance The higher the selected level for assistance, the more the drive system assists the rider when pedalling. There are four levels of assistance available. 3.6.2.2 Current speed The current speed is displayed in km/h. 3.6.2.3 System message The drive system monitors itself continuously and if an error is detected, it is indicated by a system message. -
Page 37: Technical Data
Technical data Technical data Bicycle Transportation temperature 5 °C–25 °C Ideal transportation temperature 10 °C–15 °C Storage temperature 5 °C–25 °C Ideal storage temperature 10 °C–15 °C Operation temperature 5 °C–35 °C Working environment temperature 15 °C–25 °C Charging temperature 10 °C–30 °C Power output/system 250 W (0.25 kW) - Page 38 Technical data Display Storage temperature 5 °C–25 °C Charging ambient temperature 10 °C–30 °C Table 14: Display technical data Emissions A-weighted emission sound pressure level < 70 dB(A) Total vibration level for the hands and arms < 2.5 m/s² Highest effective value of weighted <...
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Page 39: Transportation, Storage And Assembly
Transportation, storage and assembly Transportation, storage and assembly Transportation Cr as h c au s ed by un i nte n tion a l ac tiv a tion CAUTION There is a risk of injury if the drive system is activated unintentionally. - Page 40 Transportation, storage and assembly Bicycle rack systems which secure the bicycle NOTICE standing on its head by the handlebars or frame, generate inadmissible forces on the components during transportation. This can cause the supporting parts to break. Never use bicycle rack systems which secure the bicycle standing on its head by the handlebars or frame.
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Page 41: Using The Transport Securing System
Transportation, storage and assembly 5.1.1 Using the transport securing system Insert the transport securing devices between the brake linings. The transport securing device is squeezed between the two linings. Figure 11: Fastening the transport securing device Storing Ri sk o f f ir e an d e x pl os ion d ue to hi gh CAUTION t em p e rat u r e s Excessively high temperatures damage the battery. -
Page 42: Break In Operation
Transportation, storage and assembly If the bicycle features a hydraulic seat post, fix only the lower seat post or the frame into a fitting stand to prevent damage to the upper seat post and the seat post lever. Never place a bicycle with a hydraulic seat post upside down on the floor;... -
Page 43: Preparing A Break In Operation
Transportation, storage and assembly 5.2.1.1 Preparing a break in operation Remove the battery from the bicycle. Charge the battery to around 60% (three to four LEDs of the charge status indicator light up). The bicycle has to be cleaned with a damp cloth and preserved with wax spray. -
Page 44: Assembly
Transportation, storage and assembly Assembly Crushing caused by unintentional activation CAUTION There is a risk of injury if the drive system is activated unintentionally. Remove the battery if the battery is not absolutely necessary for assembly. Assemble the bicycle in a clean and dry environment. ... -
Page 45: Unpacking
Transportation, storage and assembly 5.3.2 Unpacking Hand injuries caused by cardboard packaging CAUTION The shipping carton is closed with metal staples. There is a risk of puncture wounds and cuts when unpacking and crushing the packaging. Wear suitable hand protection. ... -
Page 46: Commissioning
Transportation, storage and assembly 5.3.4 Commissioning Fire and explosion caused by incorrect charger CAUTION Batteries which are charged with an unsuitable charger, may become internally damaged. This may result in fire or an explosion. Only ever use the battery with the supplied charger. ... - Page 47 Transportation, storage and assembly Initial commissioning check list Check the battery The battery is supplied partially charged. Fully charge the battery to ensure full power Mount the wheels, quick release and pedals. Re-adjust the quick release clamping force if necessary. Thoroughly degrease the brake discs in disc brakes or the brake ...
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Page 48: Checking The Battery
Transportation, storage and assembly 5.3.4.1 Checking the battery Risk of fire and explosion due to faulty battery WARNING The safety electronics on damaged or faulty batteries may fail. The residual voltage can cause a short circuit. The batteries may self-ignite and explode. ... -
Page 49: Checking The Stem And Handlebars
Transportation, storage and assembly 5.3.4.2 Checking the stem and handlebars Checking connections Stand in front of the bicycle to check whether the handlebars, stem and fork shaft are firmly attached to one another. Clamp the front wheel between your legs. Grasp the handlebar grips. Try to twist the handlebars towards the front wheel. -
Page 50: Sale Of The Bicycle
Transportation, storage and assembly Checking the headset backlash To check the handlebar headset backlash, close the quick release lever on the stem. 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 bicycle backwards and forwards. -
Page 51: Before The First Ride
Always observe the indicated torques on the screw or in the operating instructions. Only a correctly adjusted bicycle will guarantee you the desired ride comfort and health-promoting activity. Therefore adjust the saddle, the handlebars and the suspension to your body and your preferred riding style before the first ride. -
Page 52: Determining The Seat Height
Before the first ride Place the saddle tilt in the horizontal position to adjust the bicycle to your needs for the first time. Figure 12: Horizontal saddle tilt 6.1.2 Determining the seat height To determine the seat height safely, either push the bicycle near to a wall, so that you can lean on the wall to support yourself or ask another person to hold the bicycle for you. -
Page 53: Adjusting The Seat Height With Quick Release
Before the first ride Figure 13: Optimal saddle height 6.1.3 Adjusting the seat height with quick release Open the quick release on the seat post to change the seat height. To do so, pull the clamping lever away from the seat post. Figure 14: Seat post quick release (3) with clamping lever (5) and setting bolt (4) in the open position (1) and in the direction of the closed... - Page 54 Before the first ride Set the seat post at the required height. Crash caused by an excessively high seat post CAUTION setting A seat post with is set too high will cause the seat post or the frame to break. This will result in a crash and injuries.
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Page 55: Setting The Height-Adjustable Seat Post
Before the first ride 6.1.4 Setting the height-adjustable seat post When using your seat post for the first time, you must give it a firm push downwards to set it in motion. This is due to the natural tendency of the seal to repel oil from the seal surface. -
Page 56: Adjusting The Seat Position
Before the first ride 6.1.5 Adjusting the seat position The saddle can be shifted on the saddle frame. The right horizontal position ensures an optimal leverage position for legs. This prevents knee pain and painful incorrect pelvis positions. If you have displaced the saddle more than 10 mm, you then need to adjust the saddle height again since both settings affect one another. -
Page 57: Setting The Handlebars
Before the first ride Setting the handlebars The handlebars must only be adjusted while the bicycle is stationary. Unfasten and adjust the designated screw connections, and clamp them with the maximum tightening torque for the clamping screws of the handlebars. -
Page 58: Adjusting The Handlebar Height
Before the first ride 6.2.1 Adjusting the handlebar height Crash caused by incorrectly set clamping force CAUTION Excessively high clamping force will damage the quick release and cause it to lose its function. Insufficient clamping force will cause a detrimental transmission of force. -
Page 59: Turning The Handlebars To The Side
Before the first ride 6.2.2 urning the handlebars to the side Alternative Crash caused by incorrectly set clamping force CAUTION Excessively high clamping force will damage the quick release and cause it to lose its function. Insufficient clamping force will cause a detrimental transmission of force. -
Page 60: Checking The Clamping Force Of The Quick Releases
Before the first ride 6.2.2.1 Checking the clamping force of the quick releases Open and close the quick releases on the stem or the seat post. The clamping force is sufficient if the clamping lever can be moved easily from the open final position into the middle and has to be pressed with the fingers or base of the thumb from the middle point onwards. -
Page 61: Adjusting The Grip Distance
Before the first ride The brake lever moves closer to the handlebar grip. Re-adjust the grip distance as necessary. The lever pressure point activates sooner. Figure 20: Using the twist knob (1) to adjust the pressure point 6.3.2 Adjusting the grip distance Crash caused by incorrectly set grip distance WARNING... -
Page 62: Adjusting The Grip Distance On A Magura Brake Lever
Before the first ride Figure 21: Brake lever grip distance 6.3.2.1 Adjusting the grip distance on a Magura brake lever (Alternative version) Use a T25 TORX® wrench to turn the setting screw to adjust the grip distance. Turn the setting screw in the minus (-) direction. ... -
Page 63: Retracting Brake Linings
Before the first ride Retracting brake linings New brake linings take time to break in and adjust to their final braking force. Accelerate bicycle to about 25 km/h. Brake bicycle until it comes to a halt Repeat process 30–50 times. ... -
Page 64: Operation
Operation Operation Crash caused by loose clothing CAUTION Laces, scarves and other loose items may become entangled in the spokes on the wheels and the chain drive. Such damage may cause you to fall from the bicycle and injure yourself. ... - Page 65 Operation You can be ride the bicycle within a temperature range between 5 °C and 35 °C. The effectiveness of the drive system is restricted outside of this temperature range. Operation temperature 5 °C–35 °C Moisture penetrating at low temperatures may impair individual bicycle functions due to the open structural design.
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Page 66: Before Each Ride
Operation Before each ride Crash caused by difficult-to-spot damage CAUTION If the bicycle topples over or you have a fall or an accident, there may be difficult-to-spot damage to components such as the brake system, quick releases or frame. Such damage may cause you to fall from the bicycle and injure yourself. -
Page 67: Check List Before Each Ride
Operation Check list before each ride Check the bicycle before each ride. Do not use the bicycle if there are any anomalies. Check that the bicycle is complete. Check that the lighting, reflector and brake, for instance, are ... -
Page 68: Using The Kickstand
Operation Using the kickstand Crash caused by a lowered kickstand CAUTION The kickstand does not fold up automatically. There is a risk of crashing if riding with the kickstand lowered. Raise the kickstand completely before the ride. The heavy weight of the bicycle may cause the NOTICE kickstand to sink into soft ground and the bicycle may topple and crash over. -
Page 69: Battery
Operation Battery Risk of fire and explosion due to faulty battery WARNING The safety electronics on damaged or faulty batteries may fail. The residual voltage can cause a short circuit. The batteries may self-ignite and explode. Remove batteries with external damage from service immediately and never charge them. - Page 70 Operation Fire and explosion caused by short circuit CAUTION Small metal objects may jumper the electrical connections of the battery. The batteries may self- ignite and explode. Keep paper clips, screws, coins, keys and other small parts away from the battery and do not insert them into the battery.
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Page 71: Integrated Battery
Operation If a key is left inserted when transporting the bicycle or NOTICE when riding, it may break off or the lock may open accidentally. Remove the key from the battery lock immediately after use. We recommend that you attach the key to a key ring. -
Page 72: Charging The Battery
Operation 7.4.2 Charging the battery Fire caused by overheated charger CAUTION The charger heats up when charging the battery. In case of insufficient cooling, this can result in fire or burns to the hands. Never use the charger on a highly flammable surface (e.g. - Page 73 Operation Connect the mains plug of the charger to a normal domestic, grounded socket. 230 V, 50 Hz Connection data Connect the charging cable to the battery's charging port. The charging process starts automatically. During the charging process the operating and charge status indicator indicates the charge status.
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Page 74: Waking The Battery
Operation 7.4.3 Waking the battery When not used for a longer period, the battery switches to sleep mode for self-protection. The LEDs of the operating and charge status indicator do not light up. Press the On-Off button (battery). ... -
Page 75: Electric Drive System
Operation Electric drive system 7.5.1 Switching on the drive system Crash caused by lack of readiness for braking CAUTION When it is switched on, the drive system can be activated by the application of force on the pedals. There is a risk of a crash if the drive is activated unintentionally, and the brake is not reached. -
Page 76: Operating Element With Display
Operation Operating element with display 7.6.1 Selecting the level of assistance Press the up button. The level of assistance is increased. Press the down button. The level of assistance is reduced. Brakes Crash caused by incorrect use CAUTION Handling the brake improperly can lead to loss of control or crashes, which may result in injuries. -
Page 77: Using The Brake
Operation Burns caused by heated brake CAUTION The brakes may become very hot during operation. There is a risk of burns in case of contact. Never touch the components of the brake directly after the ride. The drive force of the motor is shut off during the ride as soon as the rider no longer pedals. -
Page 78: Gear Shift
Operation Gear shift The selection of the appropriate gear is a prerequisite for a physically comfortable ride and making sure that the electric drive system functions properly. The ideal pedalling frequency is between 70 and 80 revolutions per minute. It is advisable to stop pedalling briefly when changing gears. -
Page 79: Brake
Operation Brake Hydraulic fluid can be fatal if it is swallowed and GEFAHR DANGER penetrates into the respiratory system Hydraulic fluid may leak out after an accident or due to material fatigue. Hydraulic fluid can be fatal if swallowed and inhaled. First aid treatment ... - Page 80 Operation After contact with eyes Rinse eyes under flowing water for at least ten minutes with the lids open; also rinse under lids. Consult eye doctor if pain or discomfort continues. After ingestion Rinse out mouth with water Never induce vomiting! Risk of aspiration! ...
- Page 81 Operation Crash caused by brake failure WARNING 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 as a consequence.
- Page 82 Operation Crash caused by incorrect use CAUTION Handling the brake improperly can lead to loss of control or crashes, which may result in injuries. Shift your body weight back and down as far as possible. Practise braking and emergency braking before the bicycle is used in public spaces.
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Page 83: Using The Brake Lever
Operation 7.9.1 Using the brake lever Figure 24: Front (2) and rear (1) brake lever – example: Shimano brake Pull the left brake lever for the front wheel brake and the right lever for the rear wheel brake until the desired speed is reached. -
Page 84: Maintenance
Maintenance Maintenance Cleaning check list Clean pedals after every ride Clean suspension fork and, if necessary, rear after every ride frame damper Cleaning the battery once a month every Chain (mainly tarmacked road) 250–300 km Basic cleaning and preservation of all at least every six ... - Page 85 Maintenance Service check list Functional check on the suspension fork Every 50 hours Suspension fork maintenance and Every 100 hours or at dismantling least every year Complete maintenance of the rear frame Every 125 hours damper Inspection by the specialist dealer every six months ...
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Page 86: Cleaning And Servicing
Maintenance Cleaning and servicing Crash and falling caused by unintentional activation CAUTION There is a risk of injury if the drive system is activated unintentionally. Remove the battery before cleaning. The following servicing measures must be performed regularly. Servicing can be performed by the operator and rider. -
Page 87: Basic Cleaning
Maintenance 8.1.2 Basic cleaning Crash caused by brake failure CAUTION The braking effect may be unusually weak temporarily after cleaning, servicing or repairing the bicycle. Such damage may cause you to fall from the bicycle and injure yourself. Never apply care products or oil to the brake discs or brake linings, or the braking surfaces on the rims. -
Page 88: Cleaning The Frame
Maintenance 8.1.2.1 Cleaning the frame Soak the dirt stains on the frame with dish-washing detergent if the dirt is thick and ingrained. After leaving it to soak for a time, remove the dirt and mud with a sponge, brush and toothbrush. ... -
Page 89: Cleaning The Drive Elements
Maintenance 8.1.2.5 Cleaning the drive elements Spray the cassette, the chain wheels and the front derailleur with a degreasing agent. Clean coarse dirt with a brush after soaking for a short time. Wash down all parts with dish-washing detergent and a toothbrush. -
Page 90: Cleaning The Battery
Maintenance 8.1.2.7 Cleaning the battery Fire and explosion caused by penetration by water CAUTION The battery is only protected from simple spray water. Penetration by water can cause a short circuit. The battery may self-ignite and explode. Never clean the battery with a high-pressure water device, water jet or compressed air. -
Page 91: Cleaning The Display
Maintenance 8.1.2.9 Cleaning the display If water enters into the display, it will be permanently NOTICE damaged. Never immerse the display in water. Never clean with a high-pressure water device, water jet or compressed air. Never use cleaning agent. ... -
Page 92: Servicing
Maintenance 8.1.3 Servicing 8.1.3.1 Servicing the frame Dry frame after cleaning Spray with care oil Clean off the care oil again after a short time. 8.1.3.2 Servicing the stem Apply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point. -
Page 93: Servicing The Drive Elements
Maintenance 8.1.3.7 Servicing the drive elements Service Maintain front and rear derailleur articulated shafts and jockey wheels with Teflon spray. 877-00136_1.0_17.09.2018... -
Page 94: Maintenance
Maintenance Maintenance Crash and falling caused by unintentional activation CAUTION There is a risk of injury if the drive system is activated unintentionally. Remove the battery before maintenance. The following maintenance measures must be carried out regularly [ Check list, page 84]. They can be ... -
Page 95: Brake System
Maintenance • The rims with visible wear indicator are worn as soon as the black, all-round groove on the pad friction surface is no longer visible. We recommend that you also replace the rims with every second brake lining replacement. ... -
Page 96: Stem
Maintenance 8.2.5 Stem The stem and quick release system should be inspected at regular intervals. The specialist dealer should adjust them if necessary. If the hexagon socket head screw is also loosened, the headset backlash also needs to be adjusted. Medium-strength thread locker, such as Loctite blue, then needs to be applied to the loosened screws and the screws tightened as per the... -
Page 97: Usb Port
Maintenance 2 cm Figure 25: Checking the chain and belt tension If a hub gear is featured, the rear wheel must be pushed backwards or forwards to tighten the chain. This should be done by a specialist only. 8.2.7 USB port Any moisture which enters through the USB port may NOTICE... -
Page 98: Service
Maintenance Service Crash and falling caused by unintentional activation CAUTION There is a risk of injury if the drive system is activated unintentionally. Remove the battery before the service. Crash caused by material fatigue CAUTION If the service life of a component has expired, the component may suddenly fail. - Page 99 Maintenance The specialist dealer will fully inspect the interior and exterior of the rear frame damper, overhaul the rear frame damper, replace all air seals of air forks, overhaul the air suspension, change the oil and replace the dust wipers. ...
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Page 100: Adjusting And Repairing
Maintenance Adjusting and repairing Crash and falling caused by unintentional CAUTION activation There is a risk of injury if the drive system is activated unintentionally. Remove the battery before the service. 8.4.1 Use original parts and lubricants only The individual parts of the bicycle have been selected carefully and to matched to each other. -
Page 101: Wheel Quick Release
Maintenance 8.4.2 Wheel quick release Crash caused by unfastened quick release CAUTION A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel. This will cause a crash. Install the front wheel quick release lever on the opposite side to the brake disc. -
Page 102: Clamping The Quick Release
Maintenance The clamping lever for the quick release is marked OPEN and CLOSE. If you can read the word OPEN, the quick release is open. If you can read the word CLOSE, the quick release is clamped. The wheel clamping lever is clamped if the clamping lever can be moved easily from the open final position into the middle and has to be pressed with the fingers or base of the thumb from the... - Page 103 Maintenance Checking and setting the clamping force of the quick releases If the clamping lever cannot be moved into its proper final position by pushing it with the hand, or if it is too loose, its clamping force will need to be readjusted. ...
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Page 104: Adjusting The Tyre Pressure
Maintenance 8.4.3 Adjusting the tyre pressure 8.4.3.1 Dunlop valve The tyre pressure cannot be measured on the simple Dunlop valve. The tyre pressure is therefore measured in the filling hose when pumping slowly with the bicycle pump. It is recommendable to use a bicycle pump with a pressure gauge. -
Page 105: Presta Valve
Maintenance 8.4.3.2 Presta valve It is recommendable to use a bicycle pump with a pressure gauge. The operating instructions for the bicycle pump must be adhered to. Unscrew and remove the valve cap. Open the knurled nut around four turns. ... -
Page 106: Schrader Valve
Maintenance 8.4.3.3 Schrader valve It is recommendable to use a bicycle pump with a pressure gauge. The operating instructions for the bicycle pump must be adhered to. Unscrew and remove the valve cap. Connect the bicycle pump. ... -
Page 107: First Aid For System Messages
Maintenance 8.4.4 First aid for system messages F ire a n d e xp l o s io n d ue to fa u lty ba tte rie s WARNING The safety electronics on damaged or faulty batteries may fail. The residual voltage can cause a short circuit. -
Page 108: Specific Error Eradication
Maintenance Re-start the drive system. If the system message is still displayed, contact the KETTLER specialist dealer. 8.4.4.2 Specific error eradication Make a note of the system message. Error Remedy Charge the battery. Charge the battery. -
Page 109: Accessories
Maintenance Accessories For bicycles without a kickstand we recommend a parking stand into which either the front or rear wheel can be inserted securely. The following accessories are recommended: Description Article number Teddy child seat 08947-665 Flipper child seat 08947-660 Fitting stand 08981-880 Wall mount... -
Page 110: Child Seat
Maintenance 8.5.1 Child seat Crash due to incorrect child seat WARNING Neither the pannier rack nor the bicycle down tube are suitable for child seats and may break. Such an incorrect position may cause a crash with serious injuries for the rider and the child. ... -
Page 111: Bicycle Trailer
Maintenance The specialist dealer will advise you on the choice of right child seat system for the child and the bicycle. The specialist dealer must mount the child seat the first time to ensure that it is safely fitted. When installing a child seat, the specialist dealer makes sure that the seat and the fastening mechanism for the seat are suitable for the bicycle and that all components are installed and firmly fastened. -
Page 112: Pannier Rack
Maintenance which do not exceed the permitted values, must be used. Figure 30: Trailer sign The specialist dealer will advise you on the choice of the right trailer system for the bicycle. The specialist dealer must install the trailer the first time to ensure that it is safely fitted. -
Page 113: Recycling And Disposal
Recycling and disposal Recycling and disposal Risk of fire and explosion WARNING The safety electronics on damaged or faulty batteries may fail. The residual voltage can cause a short circuit. The batteries may self-ignite and explode. Remove batteries with external damage from service immediately and never charge them. - Page 114 Recycling and disposal This device is marked according to the European Directive 2012/19/EU on waste electrical and electronic equipment – WEEE. The directive provides the framework for the return and recycling of used devices across the EU. The bicycle, battery, display and charger are recyclable materials.
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Page 115: Appendix
EN 82079 1:2012, Preparation of instructions for use – Structuring, content and presentation – Part 1: General principles and detailed requirements. Ms. Janine Otto (Technical Editor), c/o KETTLER Alu-Rad GmbH, Longericher Str. 2, 50739 Köln, is authorised to compile the technical documentation. -
Page 116: Parts List
Appendix 10.2 Parts list Model 2° E Beltdrive Type number KU117-VAFD50, KU117-VAFD55, KU117-VAFD60, KU117-VAFT45, KU117-VAFT50 Wheel size 28" Drive Belt drive Motor Suntour EBHM17; rear wheel hub motor Gears Shimano BR-MT200; hydraulic disc brake Rechargeable battery BMZ Evo Intube Stem Kalloy ML-2;... - Page 117 Appendix Model 2° E Comp Type number KU119-VAFD50, KU119-VAFD55, KU119-VAFD60, KU119- VAFT45, KU119-VAFT50 Wheel size 28" Drive Chain drive Motor Suntour EBHM17; rear wheel hub motor Gears Shimano Deore 9-gear derailleur Rechargeable battery Shimano BR-MT200; hydraulic disc brake Stem BMZ Evo Intube Fork Kalloy ML-2;...
- Page 118 Appendix Model 2° E Compact Type number KU121-VAFD46 Wheel size 20" Drive Belt drive Motor Suntour EBHM17; rear wheel hub motor Gears Single gear Rechargeable battery Shimano BR-MT200; hydraulic disc brake Stem BMZ Evo Intube Fork Kalloy ML-2; monkeylink ready Seat post Rigid fork, alloy Tyres...
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Page 119: Table Of Figures
Appendix 10.3 Table of figures Figure 1: Type plate, example, 17 Figure 2: Bicycle viewed from the right, 2° E Beltdrive used as example, 24 Figure 3: Detailed view of bicycle from rider position, example, 25 Figure 4: Components of the wheel – example showing front wheel, 27 Figure 5: Rim brake components with details –... - Page 120 Appendix Figure 27: Dunlop valve with union nut (1) and rim nut (2), 104 Figure 28: Presta valve with valve insert (1), knurled nut (2) and rim nut (3), 105 Figure 29: Schrader valve with rim nut (1), 106 Figure 30: Trailer sign, 112 877-00136_1.0_17.09.2018...
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Page 121: Subject Index
Appendix 10.4 Subject index Down tube battery, Alternative equipment, 15 - removing, 71 Operating status indicator, 34 Alternative version, 16 Drive system, 31 Area of use, 14 - switching off, 75 Packaging, 45 - switching on, 75 Pannier rack, 24 Driving light, 34 Back-pedal brake, - checking, 67... - Page 122 Appendix Valve, 27 Dunlop valve, 27 Presta valve, 27 Schrader valve, 27 Weight, permitted total weight, 17 Unladen weight, 1 Wheel circumference, 1 Wheel, - maintaining, 94 Winter break, see break in operation Working environment, 44 877-00136_1.0_17.09.2018...
- Page 123 Text and images: ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Straße 2 50739 Köln, Germany Translation: Tanner Translations GmbH+Co Markenstraße 7 40227 Düsseldorf, Germany Operating instructions: 877-00136 • 1.0 • 13.09.2018...
- Page 124 KETTLER Alu-Rad GmbH Longericher Straße 2 50739 Köln, Germany Tel.: +49 6805 6008 0 Fax: +49 6805 6008 3098 E-mail: info@kettler-alu-rad.de YOUR KETT LER SPECIALIST DEALER...