Kettler 2 E Pro Street Translation Of The Original Operating Instructions
  1. Manuals
  2. Brands
  3. Kettler Manuals
  4. Bicycle
  5. 2 E Pro Street
  6. Translation of the original operating instructions

Kettler 2 E Pro Street Translation Of The Original Operating Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
TRANSLATION OF THE ORIGINAL
EN
OPERATING INSTRUCTIONS
ELECTRIC BICYCLES
2° E Pro Street, 2° E Pro Street S, 2° E Pro 5, 2° E Pro Cross
KC156-VAKxxx, KC174-VBKxxx, KC157-VAFxxx, KC158-VAKDxx
MY20K04-2 • 1.0 • 19. August 2019

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2 E Pro Street and is the answer not in the manual?

Questions and answers

Related Manuals for Kettler 2 E Pro Street

Summary of Contents for Kettler 2 E Pro Street

  • Page 1 IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS ELECTRIC BICYCLES 2° E Pro Street, 2° E Pro Street S, 2° E Pro 5, 2° E Pro Cross KC156-VAKxxx, KC174-VBKxxx, KC157-VAFxxx, KC158-VAKDxx MY20K04-2 •...
  • 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.

  • Page 4: Table Of Contents

    Contents 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 instructions 1.6.3 Warnings 1.6.4 Safety markings For your information 1.7.1 Instructions for actions 1.7.2 Information on the nameplate 1.7.3...
  • Page 5 Contents 3.3.3.1 Air suspension fork structure Brake system Electric drive system 3.5.1 Drive unit 3.5.2 Rechargeable battery 3.5.3 Control panel 3.5.3.1 Display bar 3.5.3.2 Level of assistance Charger Technical data Transportation, storage and assembly Transporting 5.1.1 Transporting the battery 5.1.2 Using the transport securing system Storing 5.2.1...
  • Page 6 Contents 6.1.5 Adjusting the seat position Adjusting the handlebars 6.2.1 Adjusting the height of the handlebars 6.2.2 Turning the handlebars to the side 6.2.2.1 Checking the clamping force of the quick releases 6.2.2.2 Adjusting the quick release clamping force Adjusting the brake lever 6.3.1 Adjusting the pressure point on a Magura brake lever 6.3.2...
  • Page 7 Contents 7.10 Suspension and damping 7.10.1 Adjusting the compression of the Suntour fork Maintenance Cleaning and servicing 8.1.1 After each ride 8.1.1.1 Cleaning the suspension fork 8.1.1.2 Cleaning the rear frame damper 8.1.1.3 Cleaning the pedals 8.1.2 Basic cleaning 8.1.2.1 Cleaning the frame 8.1.2.2 Cleaning the stem...
  • Page 8 Contents 8.2.13 USB port Service Adjusting and repairing 8.4.1 Use original parts and lubricants only 8.4.2 Axle with quick release 8.4.2.1 Checking the quick release 8.4.3 Adjusting the tyre pressure 8.4.3.1 Dunlop valve 8.4.3.2 Presta valve 8.4.3.3 Schrader valve 8.4.4 Adjusting the gear shift 8.4.5 Cable-operated gear shift, single-cable...

  • 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: • 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 online at www.kettler-alu-rad.de. The specialist dealer authorised to perform repairs and maintenance work receives regular training.

  • Page 13: Basic Safety Instructions

    About these instructions 1.6.2 Basic safety instructions These operating instructions have a chapter with general safety instructions [ Chapter 2, page 18].  You can distinguish this chapter as it has a grey background. 1.6.3 Warnings Hazardous situations and actions are marked with warnings.

  • Page 14: Safety Markings

    About these instructions 1.6.4 Safety markings The following safety markings are used on the bicycle's nameplates: General warning Adhere to the instructions for use Table 2: Meaning of safety markings For your information 1.7.1 Instructions for actions Instructions for actions are structured in accordance with the following pattern: ...
  • Page 15 About these instructions Suitable for tarmacked and paved roads – no off-road riding or jumps. Suitable for tarmacked roads, cycle paths and firm gravel paths and roads, longer sections with moderate slopes and jumps up to 15 cm. Suitable for tarmacked roads, cycle paths and easy to demanding off-road riding, sections with moderate slopes and jumps up to 61 cm.
  • Page 16 About these instructions Read the instructions Separate collection of electrical and electronic devices Separate collection of ordinary and rechargeable batteries Must not be thrown into fire (burning prohibited) It is forbidden to open batteries Device of protection class II Only suitable for use indoors Fuse (device fuse) EU conformity Recyclable material...

  • Page 17: Language Conventions

    About these instructions 1.7.3 Language conventions The bicycle described in these operating instructions may be equipped with alternative components. The equipment of the bicycle is defined by the respective type number. Where applicable, the word Alternative beneath the heading indicates alternatively used components.

  • Page 18: Nameplate

    About these instructions Nameplate The nameplate is situated on the frame. The nameplate features the following information: KETTLER Alu-Rad GmbH Longericher Str. 2 50739 Köln, Germany Typ: 20-16-0001 EPAC nach EN 15194 0,25 kW / 25 km/h zGG 180 kg...

  • 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: 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 rider's physical and mental abilities must be adequate to use a muscle-powered bicycle.

  • Page 21: 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 riding light, reflectors and other components.

  • Page 22: City And Trekking Bicycle

    Safety • when the electrical drive has been manipulated • when the permitted gross load weight is exceeded • riding with a damaged or incomplete bicycle • riding over steps • riding through deep water • lending the bicycle to untrained riders •...

  • Page 23: 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 24 Safety The printed EC Declaration of Conformity in the appendix is valid providing that the bicycle remains unchanged from its original condition. As soon as the operator makes any relevant modifications or additions, they legally become the manufacturer. He must independently guarantee compliance with the EC directives again in order to: •...

  • Page 25: Description Overview

    Description Description Overview Figure 2: Bicycle viewed from the right, 2° E Pro 5 used as example Front wheel Fork Front mudguard Handlebars Headlight Stem Frame Seat post Saddle Rear mudguard Rear light and reflector Rear wheel Chain Rechargeable battery, frame number and nameplate MY20K04-2_1.0_19.08.2019...

  • Page 26: Handlebars

    Description Handlebars Figure 3: Detailed view of bicycle from rider position, example Rear brake lever Front brake lever Control panel Fork lock on suspension fork head Shifter MY20K04-2_1.0_19.08.2019...

  • 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.

  • Page 29: Suspension

    Description 3.3.2 Suspension Both forks and suspension forks are fitted in this model series. A suspension fork is based either on a steel spring or air suspension. Unlike a rigid fork, a suspension fork has two functions which improve floor contact and comfort: suspension and damping.

  • Page 30: Suspension Fork Structure

    Description Dampers which dampen compressive deflection movements, i.e. a compression load, are called compression dampers or compression dashpots. Dampers which dampen rebound deflection movements, i.e. a rebound load, are called rebound dampers or dashpots. 3.3.3 Suspension fork structure Figure 6: Example showing Suntour fork: The stem and handlebars are fastened to the fork steerer (1).

  • Page 31: Air Suspension Fork Structure

    Description 3.3.3.1 Air suspension fork structure The vehicle's fork features both air suspension and a compression damper plus a rebound damper in some cases. Figure 7: Air suspension fork structure, Suntour Diagram with the operating elements: Air valve (1), valve cap (2) fork lock (3), quick release (4) and rebound damper adjuster (5) and the assembly groups: Air suspension fork (A), compression damper assembly...

  • Page 32: Brake System

    Description Brake system The bicycle's brake system comprises a hydraulic rim brake on both the front and rear wheel. Figure 8: Bicycle brake system with a disc brake, example Brake disc Brake calliper with brake linings Handlebars with brake levers Front wheel brake disc Rear wheel brake disc On a bicycle with a disc brake, the brake disc is...

  • Page 33: Electric Drive System

    Description Electric 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 34 Description The electric drive system is made up of 5 components: Figure 10: Diagram of electric drive system Control panel Bottom-bracket gears Drive unit Rechargeable battery A charger which is designed for the battery. MY20K04-2_1.0_19.08.2019...

  • Page 35: Drive Unit

    Description 3.5.1 Drive unit Figure 11: Drive unit 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. The motor force is determined by the set level of assistance.

  • Page 36: Rechargeable Battery

    Description 3.5.2 Rechargeable battery Figure 12: Rechargeable battery, view of charging port side Charging port On-Off button Battery level indicator (battery) The lithium ion battery has an internal electronic protection circuit. This is matched to the charger and bicycle motor. The battery temperature is monitored at all times.
  • Page 37 Description The battery's service life can be extended if it is well maintained and, above all, stored at the correct temperatures. The charging capacity will decrease with age, even if the battery is maintained properly. If the operating time is severely shortened after charging, this is a sign that battery has reached the end of its useful life.

  • Page 38: Control Panel

    Description 3.5.3 Control panel Figure 13: Overview of the structure and operating elements Designation Display bar Top button Middle button Bottom button Extension cable Battery level indicator or pedal assistance Status screen Table 8: Operating elements overview The control panel controls the drive system via three buttons and displays either the charge level of the battery or the pedal assistance selected.

  • Page 39: Display Bar

    Description Operating temperature -20 ... +60 °C Storage temperature -20 ... +60 °C Protection rating IP54 (with USB cover closed) Weight about 0.075 kg Table 9: Display technical data 3.5.3.1 Display bar The control panel display bar consists of 11 LEDs. The uppermost LED serves as a status display to provide information on the status of your e-bike.

  • Page 40: Level Of Assistance

    Description 3.5.3.2 Level of assistance You can adjust the desired level of assistance using the control panel. The pedal assistance can be changed at any time. The higher the level of assistance, the more the drive system assists the rider when pedalling. The following levels of assistance are available: The following levels of assistance are possible: Level of assistance...

  • Page 41: Charger

    Description Charger The lithium ion battery has an internal electronic protection circuit. It is matched to the charger. The bicycle may therefore only be charged using the charger provided. Nominal input voltage 100 ... 240 V AC Frequency 50 ... 60 Hz Output voltage 42 V DC Charging current...

  • Page 42: Technical Data

    Technical data Technical data Bicycle Transportation temperature -20 ... +60 °C Operating temperature -20 ... +60 °C Storage temperature -20 ... +60 °C Discharging temperature -20 ... +60 °C Charging temperature 0 ... +45 °C Power output/system 250 W (0.25 kW) Shut-off speed 25 km/h Weight of ready-to-ride bicycle...
  • Page 43 Technical data Rechargeable battery Type Lithium ion battery Nominal voltage 36 V Nominal capacity 7 Ah Power 252 Wh Operating temperature -20 ... +60 °C Storage temperature -20 ... +60 °C Discharging temperature -20 ... +60 °C Charging temperature 0 ... +45 °C Protection class IP 54 Weight about...
  • Page 44 Technical data Bottom-bracket gears Assistance torque, max. 60 Nm Q factor, min. 135 (without crank arm) Operating temperature -20 ... +60 °C Storage temperature -20 ... +60 °C Protection class IP 54 Chainline 49, 52 mm Weight about 1.3 kg Table 17: Bottom-bracket gears technical data Charger...
  • Page 45 Technical data Emissions A-weighted emission sound pressure level < 70 dB(A) Total vibration level for the hands and < 2.5 m/s² arms Highest effective value of weighted < 0.5 m/s² acceleration for the entire body Table 19: Emissions from the bicycle* *The safety requirements as per Electromagnetic Compatibility Directive 2014/30/EU have been met.

  • Page 46: Transportation, Storage And Assembly

    Transportation, storage and assembly Transportation, storage and assembly Transporting C r a s h c a u s e d b y u n i nt e n t i o n a l a c t i v a t i o n CAUTION There is a risk of injury if the drive system is activated unintentionally.
  • Page 47 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.

  • Page 48: Transporting The Battery

    Transportation, storage and assembly 5.1.1 Transporting the battery Batteries are subject to hazardous goods regulations. Undamaged batteries may be transported by private persons in road traffic. Commercial transport requires compliance with regulations concerning packaging, labelling and the transportation of hazardous goods. Open contacts must be covered and the battery securely packaged.

  • Page 49: Storing

    Transportation, storage and assembly Storing R i s k o f f i r e a n d e x p l o s i o n d u e t o h i g h CAUTION t e m p e r a t u r e s Excessively high temperatures will damage batteries.

  • Page 50: Break In Operation

    Transportation, storage and assembly 5.2.1 Break in operation The battery discharges when not in use. Storing a NOTICE discharged battery for longer periods can cause serious damage to your battery or significantly reduce its capacity. The battery may become damaged if it is connected NOTICE permanently to the charger.

  • Page 51: 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 it is not absolutely necessary for assembly.  Assemble the bicycle in a clean and dry environment. ...

  • Page 52: 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 53: Commissioning

    Transportation, storage and assembly 5.3.4 Commissioning Risk of fire and explosion due to incorrect charger CAUTION Batteries which are recharged with an unsuitable charger may become damaged internally. This may result in fire or an explosion.  Only ever use the battery with the supplied charger. ...
  • Page 54 Transportation, storage and assembly Initial commissioning check list  Check battery. The battery is partially charged when delivered. 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 ...

  • Page 55: 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 may fail if the batteries are damaged or faulty. The residual voltage can cause a short circuit. The battery may self-ignite and explode. ...

  • Page 56: Installing The Wheel In The Suntour Fork

    Transportation, storage and assembly 5.3.5 Installing the wheel in the Suntour fork Alternative 5.3.5.1 Installing the wheel with screw-on axle (15 mm) Alternative  Insert the axle completely on the drive side. Figure 15: Fully inserting the axle  Tighten the axle with a 5 mm hexagon socket spanner to 8–10 Nm.
  • Page 57 Transportation, storage and assembly  Insert the securing screw on the non-drive side. Figure 17: Pushing the quick release lever into the axle  Tighten the securing screw with a 5 mm hexagon socket spanner to 5–6 Nm.  The lever is mounted. Figure 18: Tightening the securing screw MY20K04-2_1.0_19.08.2019...

  • Page 58: Installing The Wheel With Screw-On Axle (20 Mm)

    Transportation, storage and assembly 5.3.5.2 Installing the wheel with screw-on axle (20 mm) Alternative  Insert the axle completely on the drive side. Figure 19: Tightening the inserted axle  Tighten the securing clip with a 4 mm hexagon socket spanner to 7 Nm. Figure 20: Tightening the axle MY20K04-2_1.0_19.08.2019...

  • Page 59: Installing The Wheel With A Quick Release Axle

    Transportation, storage and assembly 5.3.5.3 Installing the wheel with a quick release axle Alternative Crash caused by loose quick release axle CAUTION A faulty or incorrectly installed quick release axle may become caught in the brake disc and block the wheel. This will cause a crash.
  • Page 60 Transportation, storage and assembly  Insert the axle into the hub on the drive side. Clamping version II. Figure 21: Pushing the axle into the hub  Tighten the axle with the red handle. Figure 22: Tightening the axle MY20K04-2_1.0_19.08.2019...
  • Page 61 Transportation, storage and assembly  Push the quick release lever into the axle. Figure 23: Pushing the quick release lever into the axle  Reverse the quick release lever.  The lever is secured. Figure 24: Securing the lever MY20K04-2_1.0_19.08.2019...
  • Page 62 Transportation, storage and assembly  Check the position and clamping force of the quick release lever. The quick release lever must be flush with the lower housing. You must be able to see a slight impression on the palm of your hand when you close the quick release lever.

  • Page 63: Installing The Wheel With A Quick Release

    Transportation, storage and assembly 5.3.6 Installing the wheel with a quick release Alternative 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. ...
  • Page 64 Transportation, storage and assembly  Before installing, ensure that the quick release flange is extended. Open the lever completely. Figure 27: Closed and opened flange  Push in the quick release until you hear a clicking sound. Make sure that the flange is extended. Figure 28: Pushing the quick release in MY20K04-2_1.0_19.08.2019...
  • Page 65 Transportation, storage and assembly  Adjust the clamping with a half-open clamping lever until the flange reaches the fork end. Figure 29: Adjusting the clamping  Fully close the quick release. Check the quick release to ensure it is firmly in place and adjust on the flange if necessary.

  • Page 66: Checking The Stem And Handlebars

    Transportation, storage and assembly 5.3.6.1 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 67: Selling 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 68: Before The First Ride

    Before the first ride Before the first ride Crash caused by incorrectly adjusted torques CAUTION If a screw is fastened too tightly, it may break. If a screw is not fastened enough, it may loosen. This will cause a crash with injuries. ...

  • Page 69: Determining The Seat Height

    Before the first ride 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 70: Adjusting The Seat Height With Quick Release

    Before the first ride 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, push the clamping lever away from the seat post. Figure 33: 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 position (2)

  • Page 71: Setting The Height-Adjustable Seat Post

    Before the first ride Figure 34: Detailed view of the seat post – examples of the minimum insertion depth marking  To close it, push the seat post clamping lever as far as it will go into the seat post. ...

  • Page 72: Lowering The Saddle

    Before the first ride 6.1.4.1 Lowering the saddle  To lower the saddle, press your hand down on the saddle or sit on the saddle.  Push the seat post activation lever and hold it down.  Release the lever once you have reached the required height.

  • Page 73: Adjusting The Handlebars

    Before the first ride bring the saddle back. Move the saddle within its permitted displacement range only (marked on the saddle stay). 90° Figure 36: Knee cap perpendicular line Adjusting the handlebars  The handlebar settings must only be adjusted while the pedelec is stationary.

  • Page 74: Adjusting The Height Of The Handlebars

    Before the first ride Adjusting the stem Crash caused by loose stem CAUTION Incorrectly fastened screws may come loose due to impact. The stem may no longer be firmly fixed in its position as a result. This will cause a crash with injuries.

  • Page 75: Turning The Handlebars To The Side

    Before the first ride Figure 37: Open (2) and closed (1) clamping lever on the stem; by.schulz speedlifter used as an example 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.

  • Page 76: Checking The Clamping Force Of The Quick Releases

    Before the first ride Figure 38: Pulling locking lever upwards – by.schulz speedlifter used as an example 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. ...

  • Page 77: Adjusting The Brake Lever

    Before the first ride Adjusting the brake lever 6.3.1 Adjusting the pressure point on a Magura brake lever Brake failure due to incorrect setting WARNING If the pressure point is set with brakes where the brake linings and brake disc have reached their wear limit, the brakes may fail and cause an accident with injury.

  • Page 78: Adjusting The Grip Distance

    Before the first ride 6.3.2 Adjusting the grip distance Crash caused by incorrectly set grip distance WARNING If brake cylinders are set incorrectly or installed wrongly, the braking power may be lost at any time. This may cause a crash with injuries. ...

  • Page 79: Adjusting The Grip Distance On A Magura Brake Lever

    Before the first ride 6.3.2.1 Adjusting the grip distance on a Magura brake lever Alternative Use a T25 TORX® wrench to turn the setting screw to adjust the grip distance.  Turn the setting screw in the minus (–) direction. ...

  • Page 80: Adjusting The Suspension

    Before the first ride Adjusting the suspension Crash caused by incorrectly set suspension CAUTION If the suspension is adjusted incorrectly, the fork may become damaged, so that problems may occur when steering. This will cause a crash with injuries.  Never ride the pedelec without air in the air suspension fork.

  • Page 81: Adjusting The Steel Suspension Fork Negative Deflection

    Before the first ride 6.4.1.1 Adjusting the steel suspension fork negative deflection Alternative You can adjust the fork by tensioning the spring to the rider's weight and their preferred riding style. It is not the coil spring hardness which is adjusted; it is its pre- tensioning.

  • Page 82: Adjusting The Air Suspension Fork Negative Deflection

    Before the first ride 6.4.1.2 Adjusting the air suspension fork negative deflection Alternative Riding without filling pressure will destroy the wheel NOTICE suspension, the frame and the air suspension elements.  Never ride without filling pressure in the air suspension elements. A normal air pump cannot build up the required NOTICE pressure with sufficient sensitivity.

  • Page 83: Retracting The Brake Linings

    Before the first ride  The air valve is located under a screw cap on the head of the left shock absorber. Unscrew and remove the screw cap.  Adjust the air pressure as an initial value using a high-pressure damper pump and based on the tyre pressure table on the fork and the rider's weight.

  • Page 84: Operation

    Operation Operation Crash caused by loose clothing CAUTION Shoe laces, scarves and other loose items may become entangled in the spokes on the wheels and on the chain drive. This may cause a crash with injuries.  Wear sturdy footwear and close-fitting clothing. Risk of fire and burning due to hot motor CAUTION The motor housing becomes hot when riding.
  • Page 85 Operation Heat or direct sunlight can cause the tyre pressure to NOTICE increase above the permitted maximum pressure. This can destroy the tyres.  Never park the bicycle in the sun.  On hot days, regularly check the tyre pressure and adjust it as necessary.

  • Page 86: 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. This may cause a crash with injuries. ...

  • Page 87: 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 88: Charger

    Operation Charger Risk to life due to failure of pacemakers DANGER The magnetic connections in the charger may affect the function of pacemakers.  Never stand in proximity to the magnetic connections with a pacemaker. Fire and electric shock WARNING If the charger's supply voltage exceeds the value specified in the technical data, an electric shock or fire in the charger may occur.
  • Page 89 Operation Danger of electric shock CAUTION The charger is live during operation. Incorrect use may cause electric shock.  Never open the charger.  The charger, cable and connector must be checked before each use. Never use if damage is detected. ...

  • Page 90: Connecting The Charger To The Mains

    Operation 7.3.1 Connecting the charger to the mains  Connect the mains plug on the connecting cable to the power jack on the charger. Connect the mains plug (country-specific) on the connecting cable to the power supply. Nominal input voltage 100 ...

  • Page 91: Rechargeable Battery

    Operation Rechargeable battery Risk to life due to failure of pacemakers DANGER The magnetic connections in the battery may affect the function of pacemakers.  Never stand in proximity to the magnetic connections with a pacemaker. Risk of fire and explosion due to faulty battery WARNING The safety electronics may fail if the battery is damaged or faulty.
  • Page 92 Operation Risk of fire and explosion due to high temperatures CAUTION Excessively high temperatures will damage the battery. The battery may self-ignite and explode.  Protect the battery against heat.  Never expose the battery to sustained direct sunlight. Risk of fire and explosion due to short circuit CAUTION Small metal objects may jumper the electrical connections of the battery.
  • Page 93 Operation Risk of fire and explosion due to incorrect charger CAUTION Batteries which are recharged with an unsuitable charger may become damaged internally. This may result in fire or an explosion.  Only ever use the battery with the supplied charger. ...

  • Page 94: Charging The Battery

    Operation 7.4.1 Charging the battery Risk of fire and explosion due to faulty battery WARNING The safety electronics may fail if the battery is damaged or faulty. The residual voltage can cause a short circuit. The battery may self-ignite and explode. ...
  • Page 95 Operation Chemical burns to the skin and eyes caused by CAUTION faulty battery Liquids and vapours may leak from damaged or faulty batteries. They can irritate the airways and cause burns.  Avoid contact with leaked liquids.  Ventilate with fresh air and consult a doctor if you suffer any pain or discomfort.

  • Page 96: Charging The Battery In The Drive Unit

    Operation 7.4.1.1 Charging the battery in the drive unit  Insert the charger plug into the charging socket on the battery used in the drive unit. Figure 45: Drive unit with battery level indicator (1), charging socket (2), drive unit with battery (3), charger plug (4) and connection cable (5) ...

  • Page 97: Charging The Battery On The Bicycle

    Operation 7.4.1.2 Charging the battery on the bicycle  The drive unit is located on the bicycle.  Connect the charger plug to the bicycle charging socket. Figure 46: Drive unit (1) with battery level indicator (2), charger plug (3) and connection cable (4) ...

  • Page 98: Inserting The Battery Into The Drive Unit

    Operation 7.4.2 Inserting the battery into the drive unit Dirt causes friction when inserting the battery into the NOTICE drive unit and complicates the process.  Always clean the battery (1) and drive unit (2) before use and maintain a clean condition. Figure 47: Inserting the battery into the drive unit ...

  • Page 99: Removing The Battery From The Drive Unit

    Operation 7.4.3 Removing the battery from the drive unit Figure 48: Removing the battery from the drive unit  To remove the battery (1) from the drive unit (3), press the battery lock (2) whilst simultaneously pulling out the battery (1) from the battery holder. Drive unit 7.5.1 Installing the drive unit on the bicycle...
  • Page 100 Operation  A charged battery must be inserted in the drive unit.  (1) Position the interface to the bottom bracket axle directly under the down tube on the bicycle, in front of the free interface on the bottom bracket axle. ...

  • Page 101: Removing The Drive Unit From The Bicycle

    Operation 7.5.2 Removing the drive unit from the bicycle  When removing the drive unit, hold it firmly to NOTICE prevent it from falling out of the frame. 90° Figure 51: Unlocking the drive unit  Insert the lock (1) into the cylinder (2). ...
  • Page 102 Operation  Hold the drive unit firmly with one hand.  Press the drive unit firmly against the frame.  With the other hand, press the push button (3).  Swing the drive unit out of the frame and remove the drive unit.

  • Page 103: Drive System

    Operation Drive system 7.6.1 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 104: Drive System Standstill

    Operation 2 Drive pack  Remove the drive unit from the bicycle. 3 Rechargeable battery  Switch the battery off. 4 Standstill  Bring the bicycle to a halt.  The battery level indicator LEDs display a switch- off animation and the battery is switched off. 7.6.3 Drive system standstill The bicycle shuts down...

  • Page 105: Control Panel

    Operation Control panel Crash caused by distraction CAUTION A lack of concentration while riding increases the risk of an accident. This may cause a crash with serious injuries.  Never allow yourself to be distracted by the control panel. 7.7.1 Using the push assist system Injury from pedals or wheels CAUTION...

  • Page 106: Selecting The Level Of Assistance

    Operation  Use the control panel to set the pedal assistance to NONE.  Press and hold the bottom button on the control panel. After 2 seconds, the push assist system is activated.  To deactivate the push assist system, release the bottom button on the control panel.

  • Page 107: Gear Shift

    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 108: Brake

    Operation Brake Hydraulic fluid can be fatal if it is swallowed and 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 109 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 swallowing  Rinse out mouth with water. Never induce vomiting! Risk of aspiration! ...
  • Page 110 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.
  • Page 111 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 backwards and down as far as possible.  Practise braking and emergency braking before the bicycle is used in public spaces.

  • Page 112: Using The Brake Lever

    Operation The drive force of the motor is shut off during the ride as soon as the rider no longer pedals. The drive system does not switch off when braking.  In order to achieve optimum braking results, do not pedal while braking.

  • Page 113: Suspension And Damping

    Operation 7.10 Suspension and damping 7.10.1 Adjusting the compression of the Suntour fork Alternative The compression adjuster makes it possible to make quick adjustments to the suspension behaviour of the fork to suit changes in terrain. It is intended for adjustments made during the ride.

  • Page 114: Maintenance

    Maintenance Maintenance Cleaning check list  Clean the pedals after each ride Clean the suspension fork and, if necessary,  after each ride rear 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 115 Maintenance Service check list  Functional check on the suspension fork every 50 hours Suspension fork maintenance and every 100 hours or at  dismantling least once a year Complete maintenance of the rear frame  every 125 hours damper ...

  • Page 116: 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 before cleaning. The following servicing measures must be performed regularly. Servicing can be performed by the operator and rider.

  • Page 117: Basic Cleaning

    Maintenance 8.1.2 Basic cleaning Crash caused by brake failure CAUTION The braking effect may be unusually poor temporarily after cleaning, servicing or repairing the bicycle. This may cause a crash with injuries.  Never apply care products or oil to the brake discs or brake linings, or the braking surfaces on the rims.

  • Page 118: Cleaning The Frame

    Maintenance 8.1.2.1 Cleaning the frame  Soak 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 119: 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 120: Cleaning The Battery

    Maintenance 8.1.2.7 Cleaning the battery Risk of fire and explosion due to penetration by CAUTION water 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 121: Cleaning The Drive Unit

    Maintenance 8.1.2.9 Cleaning the drive unit Burns from hot drive CAUTION The drive cooler can become extremely hot during use. Contact may cause burns.  Leave the drive unit to cool before cleaning. If water enters into the drive unit, the unit will be NOTICE permanently damaged.

  • Page 122: Cleaning The Brake

    Maintenance 8.1.2.10 Cleaning the brake Brake failure due to water penetration WARNING The brake seals are unable to withstand high pressures. Damaged brakes can fail and cause an accident with injury.  Never clean the bicycle with a high-pressure water device or compressed air.

  • Page 123: Servicing The Fork

    Maintenance 8.1.3.3 Servicing the fork  Treat the dust seals with fork oil. 8.1.3.4 Servicing 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.

  • Page 124: 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 performed on a regular basis [ Check list, page 112].

  • Page 125: Checking The Tyres

    Maintenance 8.2.2 Checking the tyres  Check the tyres for wear. The tyre is worn if the anti-puncture protection or the carcass cords are visible.  A ZEG specialist dealer needs to change the tyre if it is worn. 8.2.3 Checking the rims ...

  • Page 126: Checking The Brake Linings For Wear

    Maintenance 8.2.5 Checking the brake linings for wear Check brake linings after brake has been fully applied 1,000 times.  Check that the brake linings are no less than 1.8 mm wide at any point and no less than 2.5 mm between the brake lining and supporting plate.

  • Page 127: Gear Shift

    Maintenance 8.2.9 Gear shift  Check the gear shift and the shifter or the twist grip setting and adjust it as necessary. 8.2.10 Stem  The stem and quick release system should be inspected at regular intervals. The specialist dealer should adjust them if necessary.

  • Page 128: Checking The Handlebar Grip Position

    Maintenance  The ideal chain tension has been achieved if the chain or the belt can be pushed a maximum of 2 cm in the middle between the pinion and the toothed wheel. The crank must also turn without resistance. 2 cm Figure 56: Checking the chain tension...
  • Page 129 Transportation, storage and assembly Service I n j u r y t o t h e e y e s WARNING Problems may arise if the settings are not made properly and you may sustain serious injuries as a result. ...
  • Page 130 Transportation, storage and assembly  The specialist dealer will inspect the bicycle for any signs of material fatigue during basic cleaning.  The specialist dealer will check the software version of the drive system and update it. The electrical connections are checked, cleaned and preservative agent is applied.
  • Page 131 Maintenance Adjusting and repairing Injury to the eyes WARNING Problems may arise if the settings are not made properly and you may sustain serious injuries as a result.  Always wear safety glasses to protect your eyes when carrying out maintenance work such as replacing components.
  • Page 132 Maintenance 8.4.2 Axle with 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 133 Maintenance 8.4.2.1 Checking the quick release  Check the position and clamping force of the quick release lever. The quick release lever must be flush with the lower housing. You must be able to see a slight impression on the palm of your hand when you close the quick release lever.
  • Page 134 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 135 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 136 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 137 Maintenance 8.4.4 Adjusting the gear shift If you cannot select the gears effortlessly, you will need to adjust the setting for the shift cable tension.  Carefully pull the adjusting sleeve away from the shifter housing, turning it as you do so. ...
  • Page 138 Maintenance 8.4.6 Cable-operated gear shift, dual-cable Alternative  For a smooth gear shift, set the adjusting sleeves underneath the chain stay on the frame.  The shift cable has around 1 mm play when it is pulled out gently. Figure 63: Adjusting sleeves (2) on two alternative versions (A and B) of a dual-cable, cable-operated gear shift on the chain stay (1) MY20K04-2_1.0_19.08.2019...
  • Page 139 Maintenance 8.4.7 Cable-operated twist grip, dual-cable Alternative  For a smooth gear shift, set the adjusting sleeves on the shifter housing.  There is noticeable play of around 2–5 mm (1/2 gear) when twisting the twist grip. Figure 64: Twist grip with adjusting sleeves (1) and play of the gear shift (2) MY20K04-2_1.0_19.08.2019...
  • Page 140 The brakes may become damaged if procedures are not followed as described. Only ZEG specialist dealers may carry out maintenance on brakes. You will find the maintenance and repair instructions at: www.kettler-alu-rad.de/de/de/index/service/anleitung MY20K04-2_1.0_19.08.2019...
  • Page 141 Transportation, storage and assembly 8.4.9 Replacing the lighting Alternatively a 3 watt or 1.5 watt lighting system can be installed.  Only use components of the respective power class for replacement. 8.4.10 Setting the headlight  The headlight must be set, so that its light beam meets the road 10 m in front of the bicycle.
  • Page 142 Maintenance 8.4.12 Initial help Risk of fire and explosion due to faulty battery WARNING The safety electronics may fail if the battery is damaged or faulty. The residual voltage can cause a short circuit. Batteries may self-ignite and explode.  Batteries with external damage must be removed from service immediately.
  • Page 143 Maintenance Colour Meaning The status screen briefly flashes green after the drive pack has been successfully installed in the Green bicycle. This gives you a visual signal that the system can now be switched on. The status screen briefly turns yellow when a "soft fault"...
  • Page 144 Maintenance 8.4.13 Drive system or control panel does not start up If the control panel and/or the drive system do not start up, proceed as follows:  Check whether the battery is switched on. If not, start the battery.  Contact specialist dealer if the battery level indicator LEDs do not light up.
  • Page 145 Maintenance Accessories We recommend a parking stand into which either the front or rear wheel can be inserted securely for bicycles which do not have a kickstand. The following accessories are recommended: Description Article number Teddy child seat 08947-665 Flipper child seat 08947-660 Fitting stand 08981-880...
  • Page 146 Maintenance 8.5.1 Child seat Crash caused by 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 147 Maintenance The specialist dealer will advise on choosing a suitable child seat system for the child and the bicycle. The specialist dealer must install 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 148 Maintenance which do not exceed the permitted values may be used. Figure 65: Trailer sign The specialist dealer will advise on choosing a suitable trailer system for the bicycle. The specialist dealer must install the trailer the first time to ensure that it is safely fitted.
  • Page 149 Recycling and disposal Recycling and disposal Risk of fire and explosion WARNING The safety electronics may fail if the batteries are damaged or faulty. The residual voltage can cause a short circuit. Batteries may self-ignite and explode.  Remove batteries with external damage from service immediately and never charge them.
  • Page 150 Recycling and disposal Hazard for the environment CAUTION The fork, rear frame damper and hydraulic brake system contain toxic and environmentally harmful oils and lubricants. Such fluids will contaminate if they enter the sewers or groundwater.  Dispose of lubricants and oils in an environmentally responsible way in accordance with statutory regulations.
  • Page 151 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 152 Appendix 10.2 Parts list Model 2° E Pro Street Type numbers KC156-VAKxxx Wheel size 28" Frame shapes Diamond Frame sizes 47cm Drive Chain drive Motor Fazua drivepack Gears Shimano XT 11-gear derailleur Brakes Shimano BR-MT 400, hydraulic disc brake Rechargeable battery Fazua in-tube battery Charger Fazua charger...
  • Page 153 Appendix Model 2° E Pro 5 Type numbers KC157-VAFxxx Wheel size 28" Frame shapes Diamond Frame sizes 47cm Drive Hub gear Motor Fazua drivepack Gears Shimano Nexus Inter 5E Brakes Shimano BR-MT 400, hydraulic disc brake Rechargeable battery Fazua in-tube battery Charger Fazua charger Stem...
  • Page 154 Appendix 10.3 Table of figures Figure 1: Nameplate, example, 16 Figure 2: Bicycle viewed from the right, 2° E Pro 5 used as example, 23 Figure 3: Detailed view of bicycle from rider position, example, 24 Figure 4: Components of the wheel – example showing front wheel, 25 Figure 5: Bicycle without suspension (1) and with suspension (2)
  • Page 155 Appendix Figure 32: Optimal saddle height, 67 Figure 33: 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 position (2), 68 Figure 34: Detailed view of the seat post – examples of the minimum insertion depth marking, 69 Figure 35: The seat post activation lever can be installed either on...
  • Page 156 Appendix Figure 57: Adjusting the quick release clamping force, 131 Figure 58: Adjusting the quick release clamping force, 131 Figure 59: Dunlop valve with union nut (1) and rim nut (2), 132 Figure 60: Presta valve with valve insert (1), knurled nut (2) and rim nut (3), 133 Figure 61: Schrader valve with rim nut (1), 134...
  • Page 157 Appendix 10.4 List of tables Table 1: Meanings of the signal words, 11 Table 2: Meaning of safety markings, 12 Table 3: Relevance of area of use, 13 Table 4: Relevance of bicycle type, 13 Table 5: Relevance of safety instructions, 14 Table 6: Identification number of the operating instructions, 17 Table 7:...
  • Page 158 Appendix 10.5 Index Pannier rack, Air valve EC declaration of conformity, - checking, 85 Fork, 29 Pedal, 31 Alternative equipment, 15 Push assist, - using, 104 Fork lock, Battery level indicator, 35 Position, 29 Battery, Fork, 25 Quick release, - charging, 92 - adjusting tyre pressure, Position, 29 - disposing of, 148...
  • Page 159 Appendix Valve cap, 29 Valve, 25 Dunlop valve, 25 Presta valve, 25 Schrader valve, 25 Weight, permitted total weight, 16 Unladen weight, 1 Wheel circumference, 1 Wheel, - maintaining, 122 Working environment, 49, 127, 129 MY20K04-2_1.0_19.08.2019...
  • Page 160 Text and images: KETTLER Alu-Rad GmbH Longericher Straße 2 50739 Köln, Germany Translation: Tanner Translations GmbH+Co Markenstraße 7 40227 Düsseldorf, Germany MY20K04-2 • 1.0 • 19. August 2019...
  • Page 161 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...

This manual is also suitable for:

2 e pro street s2 e pro 52 e pro cross

Table of Contents