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Hercules SHIMANO SC-E800 Manual

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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Translation of original operating instructions for
HERCULES pedelecs with SHIMANO SC-E800
on-board computer
NOS FS 2.1
22-R-0001
MY22 H03 - 32_1. 0_ 0 4.10.20 21

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  • Page 1 IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE Translation of original operating instructions for HERCULES pedelecs with SHIMANO SC-E800 on-board computer NOS FS 2.1 22-R-0001 MY22 H03 - 32_1. 0_ 0 4.10.20 21...

  • Page 2: Table Of Contents

    Contents Contents About these operating instructions Manufacturer Laws, standards and directives Language For your information 1.4.1 Warnings 1.4.2 Markups Type number and model Frame number Identifying the operating instructions Aim of the operating instructions Safety Residual risks 2.1.1 Risk of fire and explosion 2.1.1.1 Rechargeable battery 2.1.1.2...
  • Page 3 Contents 3.3.2 Chassis 3.3.2.1 Frame 3.3.2.2 Steering system 3.3.2.3 Steering headset 3.3.2.4 Stem 3.3.2.5 Handlebars 3.3.2.6 Fork 3.3.3 Suspension 3.3.3.1 Suspension fork 3.3.3.2 Rear frame damper 3.3.3.3 RockShox rear frame damper 3.3.4 Wheel 3.3.4.1 Tyres 3.3.4.2 3.3.4.3 Valve 3.3.4.4 Spoke 3.3.4.5 Spoke nipples 3.3.4.6...
  • Page 4 Contents Transporting and storing Weight and dimensions for transportation Designated handles, lifting points Transportation 4.3.1 Using the brake transport securing system 4.3.2 Transporting the pedelec 4.3.3 Shipping a pedelec 4.3.4 Transporting the battery 4.3.5 Shipping the battery Storing 4.4.1 Break in operation 4.4.1.1 Preparing a break in operation 4.4.1.2...
  • Page 5 Contents 6.6.8 Tyres 6.6.9 Brake 6.6.9.1 Brake handle position 6.6.9.2 Brake handle tilt angle 6.6.9.3 Determining the grip distance 6.6.9.4 Grip distance on a SHIMANO ST-EF41 brake lever 6.6.9.5 Retracting the brake linings 6.6.10 Gear shift 6.6.10.1 SHIMANO shifter 6.6.11 Suspension 6.6.12 Fork sag...
  • Page 6 Contents 6.12 Straightening the quickly adjustable stem 6.13 Using the pannier rack 6.14 Raising the kickstand 6.15 Using the saddle 6.15.1 Using the leather saddle 6.16 Using the pedals 6.17 Using the multifunctional handlebars or bar ends 6.17.1 Using leather handles 6.18 Using the bell 6.19...
  • Page 7 Contents 7.3.1 On-board computer and control panel 7.3.2 Rechargeable battery 7.3.3 Motor 7.3.4 Frame, fork, pannier rack, guards and kickstand 7.3.5 Stem 7.3.6 Handlebars 7.3.7 Handles 7.3.7.1 Leather handles 7.3.8 Seat post 7.3.9 Saddle 7.3.9.1 Leather saddle 7.3.10 Tyres 7.3.11 Spokes and spoke nipples 7.3.12 7.3.13...
  • Page 8 Contents 7.5.1.7 Checking the spokes 7.5.2 Checking the brake system 7.5.2.1 Checking the hand brake 7.5.2.2 Checking the hydraulic system 7.5.2.3 Checking the Bowden cables 7.5.2.4 Checking the disc brake 7.5.3 Checking the lighting 7.5.4 Checking the stem 7.5.5 Check the handlebars 7.5.6 Checking the saddle 7.5.7...
  • Page 9 Contents Lighting 9.4.1 On-board computer error Miscellaneous 9.5.1 RockShox suspension fork 9.5.1.1 Rebound too fast 9.5.1.2 Rebounding too slowly 9.5.1.3 Suspension too soft on inclines 9.5.1.4 Excessively hard damping on bumps 9.5.2 RockShox rear frame damper 9.5.2.1 Rebound too fast 9.5.2.2 Rebounding too slowly 9.5.2.3...
  • Page 10 About these operating instructions Thank you for your trust! Copyright HERCULES pedelecs are premium quality © HERCULES GmbH bicycles. You have made an excellent choice. Distribution or reproduction of these operating Your specialist dealer will provide you with instructions and utilisation or communication of...

  • Page 11: About These Operating Instructions

    About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and HERCULES GMBH actions. You will find three warnings in the Longericher Straße 2 50739 Köln, Germany operating instructions: Tel.: +49 4473 92617 0 WARNING...

  • Page 12: Type Number And Model

    About these operating instructions Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part stamped on it (see Figure 2). The frame number of pedelecs with the type numbers: can be used to associate the pedelec with the Type no.

  • Page 13: Aim Of The Operating Instructions

    About these operating instructions Aim of the operating instructions These operating instructions are not a substitute for personal instruction by the specialist dealer supplying the bike. These operating instructions Section are an integral part of the pedelec. Therefore, if it is re-sold at a later time, they must be handed over to the subsequent owner.

  • Page 14: Safety

    Safety Safety Residual risks 2.1.1 Risk of fire and explosion 2.1.1.1 Rechargeable battery Chargers with excessive voltage damage batteries. This may cause a fire or an explosion. The safety electronics may fail if the batteries are  Only use approved batteries to charge. damaged or faulty.

  • Page 15: Electric Shock

    Safety 2.1.2 Electric shock 2.1.2.1 Damage 2.1.3.2 Incorrect tightening torque If a screw is fastened too tightly, it may break. If a Damaged chargers, cables and plug connectors screw is not fastened enough, it may loosen. This increase the risk of electric shock. will cause a crash with injuries.

  • Page 16: Malfunctions Due To Bluetooth

    Safety 2.1.6 Malfunctions due to Bluetooth® If you use the on-board computer with Bluetooth® and/or Wi-Fi®, it may cause interference with other devices, other equipment, aircraft and medical devices, such as pacemakers and hearing aids. Likewise, harm to people and animals in the immediate vicinity cannot be completely excluded.

  • Page 17: Toxic Substances

    Safety Toxic substances Requirements for riders 2.2.1 Brake fluid The rider must have the required mental capacity and physical and motor skills to ride on public Brake fluid may leak out after an accident or due roads. A minimum age of 14 years is to material fatigue.

  • Page 18: Safety Markings And Safety Instructions

    Safety Safety markings and safety What to do in an emergency instructions 2.8.1 Dangerous situation in road traffic The pedelec and battery nameplates contain  In the event of any hazards or dangers in road these safety markings and safety instructions: traffic, apply the brakes on the pedelec until it comes to a halt.

  • Page 19: Battery Vapours Emitted

    Safety 2.8.4 Battery fire After swallowing  Rinse out mouth with water. Never induce The safety electronics may fail if the battery is vomiting. Risk of aspiration. damaged or faulty. The residual voltage can cause a short circuit. The battery may self-ignite ...

  • Page 20: Description

    Description Description Proper use All check lists and instructions for actions in these regulations for the prevention of accidents and operating instructions must be met. Approved environmental protection in the respective country accessories can be installed by specialist staff. of use must be adhered to. Use the pedelec when it is in perfect, proper The rechargeable batteries are designed to working order only.

  • Page 21: Improper Use

    Description 3.1.1 Improper use Failure to adhere to the proper use poses a risk of • lending the pedelec to untrained riders • carrying other people personal injury and material damage. It is • riding with excessive baggage prohibited to use the pedelec in the following •...

  • Page 22: Permitted Total Weight (Ptw)

    About these operating instructions 3.1.2 Permitted total weight (PTW) The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is • the weight of the fully assembled pedelec • plus body weight •...

  • Page 23: Environmental Requirements

    Overview 3.1.3 Environmental requirements You can be ride the pedelec within a temperature Temperatures under -10 °C and over +60 °C must range between -10 °C and +50 °C. The electric be avoided. drive system is limited in its performance outside You must also keep within the following this temperature range.
  • Page 24 Overview The pedelec is unsuitable for the following areas of use: Child's City and bicycles/ Area of use trekking Mountain bikes Racing bicycle Cargo bike Folding bicycle bicycles for bicycles young adults Never drive off- Never drive off- Never drive off- Never drive off- Never drive off- road or perform...

  • Page 25: Nameplate

    Description Nameplate The nameplate is situated on the frame. Use of the contains thirteen pieces of information. hub gear is described in Figure 2. The nameplate Hercules GmbH Longericher Str. 2 50739 Köln, Germany Typ: 21-17-1017 EPAC nach EN 15194...

  • Page 26: Components

    Description Components 3.3.1 Overview 18 19 Figure 2: Pedelec viewed from the right Front wheel Rear wheel Front wheel hub Gear shift and rear wheel Fork Steering headset Rear wheel brake Handlebars Chain Stem Frame number Frame Motor under motor cover Rear frame damper Pedal Seat post...

  • Page 27: Chassis

    Description 3.3.2 Chassis The chassis comprises two components: • Frame and • steering system. 3.3.2.1 Frame The frame absorbs all forces which act on the pedelec from body weight, pedalling and the ground. The frame also acts as a carrier for most components.

  • Page 28: Handlebars

    Description 3.3.2.5 Handlebars 3.3.2.6 Fork The stem and handlebars are attached to the top The pedelec is steered using the handlebars. The end of the fork steerer. The axle is fastened to the handlebars are used to support the upper body fork ends.

  • Page 29: Suspension

    Overview 3.3.3 Suspension The stem and handlebars are fastened to the fork steerer. The wheel is fastened to the axle. 3.3.3.1 Suspension fork A fork deflects when a steel spring, air suspension, or both suspension types act on it. Unlike rigid forks, suspension forks improve contact with the ground and thus enhance comfort using two functions: suspension and damping.
  • Page 30 Overview Negative deflection (sag) The pedelec rebounds at a controlled speed if it is optimally adjusted. The wheel stays in contact The sag is the percentage of total spring with the ground when passing over bumps (blue deflection that is compressed by the rider’s body line).
  • Page 31 Description Rebound damping Only applies to pedelecs with this equipment Rebound damping defines the speed at which the Rebound damping needs to be increased to suspension rebounds after being loaded. achieve an optimal setting if the air pressure or Rebound damping controls the suspension fork spring stiffness are increased.
  • Page 32 Description Steel suspension fork structure Air suspension fork structure The stem and the handlebars are fastened to the Depending on the model, the air suspension fork has either fork steerer. The wheel is fastened to the axle. • an air suspension assembly group (orange) and/ •...

  • Page 33: Rear Frame Damper

    Overview 3.3.3.2 Rear frame damper A rear frame damper is primarily fitted to mountain The rear frame damper rebounds at a controlled bikes and helps to protect the pedelec and rider speed if it is optimally adjusted. The rear wheel against impacts and vibrations caused by uneven does not bounce off rough surfaces or the ground;...
  • Page 34 Overview When optimally adjusted, the rear frame damper The saddle rises slightly when absorbing a bump deflects quickly and unhindered when the bike hits (green line). bumps and absorbs a bump. Traction is retained (blue line). Figure 18: Optimum rear frame damper ride performance over bumps MY22H03 - 32_1.0_04.10.2021...
  • Page 35 Description Rebound damping for rear frame damper Only applies to pedelecs with this equipment The rear frame damper rebounds at a controlled position when the next bump is absorbed. The speed if it is optimally adjusted. The rear wheel suspension motion is predictable and controlled. does not bounce off rough surfaces or the ground;...

  • Page 36: Rockshox Rear Frame Damper

    Description 3.3.3.3 RockShox rear frame damper The rear frame damper features air suspension, a compression damper and a rebound damper. Figure 21: Monarch RL as an example Threshold lever Rebound damper adjuster Air valve O-ring Scale MY22H03 - 32_1.0_04.10.2021...

  • Page 37: Wheel

    Description 3.3.4 Wheel If a tyre with a deep tread is used on asphalt, this may make an unpleasant noise when the brakes are used In such a case, the specialist dealer needs to replace the tyre with a new one with a shallow tread.

  • Page 38: Spoke

    Description The pedelec has either: Schrader valve • a conventional valve The Schrader valve can be pumped at filling • a Presta valve or stations. Older and easy bicycle pumps are • a Schrader valve. unsuitable for filling tyres via a Schrader valve. Dunlop valve The Dunlop valve, also known as a conventional valve, is the valve in most widespread use.

  • Page 39: Braking System

    Description 3.3.5 Braking system A pedelec's brake system is primarily operated 3.3.5.2 Hydraulic brake using the brake lever on the handlebars. The brake fluid is in a closed hose system. If the brake lever is pulled, the brake fluid transfers •...

  • Page 40: Disc Brake

    Description 3.3.5.3 Disc brake Figure 29: Brake system with disc brake – example Brake disc Brake calliper with brake linings Handlebars with brake lever Front wheel brake disc Rear wheel brake disc On a pedelec with a disc brake, the brake disc is screwed permanently to the wheel hub.

  • Page 41: Seat Post

    Description 3.3.6 Seat post Seat posts are not designed to fasten the saddle Patent saddle posts are fastened into the seat but also to adjust exactly to the optimum sitting tube with either a quick release or a screwable position. The seat post can: clamp.

  • Page 42: Mechanical Drive System

    Description 3.3.7 Mechanical drive system The pedelec is driven by muscle power, just like a 3.3.7.1 Chain drive layout bicycle. The force which is applied by pedalling in the direction of travel drives the front chain wheel. The chain or belt transmits the force onto the rear chain wheel and then onto the rear wheel.

  • Page 43: Electric Drive System

    Overview 3.3.8 Electric drive system 3.3.8.1 Motor As soon as the muscle power required for The pedelec has an electric drive system in pedalling passes a certain level, the motor is addition to a mechanical one. activated gently and assists the pedalling motion. The motor force is determined by the set level of assistance.

  • Page 44: Rechargeable Battery

    Overview 3.3.9 Riding light 3.3.8.3 Rechargeable battery The lithium ion battery has an interior electronic When the riding light is activated, the headlight protection circuit, which is specifically designed and the rear light are switched on together. for the charger and the pedelec. The battery The light is controlled using the light button on the temperature is monitored at all times.

  • Page 45: On-Board Computer

    Overview 3.3.10.1 On-board computer 3-switch control panel The SC-EM800 on-board computer controls the drive system with two operating elements, and displays the journey data. Figure 39: 3-switch control panel 2-switch control panel Figure 37: Overview of SC-EM800 on-board computer 3.3.10.2 Control panel The electric drive system is operated using the on- board computer (II) and the left-hand control panel (I).

  • Page 46: Description Of Controls And Screens

    Description Description of controls and screens 3.4.1 Handlebars 5 67 Figure 42: Detailed view of handlebars with SHIMANO SC-E800 on-board computer, used as example Rear wheel hand brake Air valve Front wheel hand brake Lock out Handle On-board computer Control panel Shifter MY22H03 - 32_1.0_04.10.2021...

  • Page 47: On-Board Computer

    Operation 3.4.2 On-board computer 3.4.2.1 Main screen After starting up, the main display screen The on-board computer has one button (1) and a appears. The main display screen has eight display screen (2). displays: Figure 43: SC-EM800 on-board computer details Figure 44: Overview of main display screen Function Shift mode indicator...
  • Page 48 Operation 4. Maintenance indicator 7. Current level of assistance indicator Indicates that maintenance is required. The selected level of assistance differs depending on the pedelec. The higher the selected level of  Contact your specialist dealer. assistance, the more the drive system assists with pedalling.

  • Page 49: Warnings And Errors

    Operation 3.4.3 Warnings and errors The drive system monitors itself continuously and if an error is detected, it is indicated by a system message. The system may switch off automatically depending on the type of error. You will find more information and a table containing all system messages in Section 6.3.

  • Page 50: Gear Shift

    Operation 3.4.4 Gear shift There is either a switch control panel or a shifter MTB control panel on the right side of the handlebars. There can be three different switches, depending on the model: • 3-switch control panel • 2-switch control panel or •...
  • Page 51 Operation SHIMANO shifter SL-M8100 Figure 49: Shifter SL-M8100 Shifter MY22H03 - 32_1.0_04.10.2021...

  • Page 52: Hand Brake

    Description 3.4.5 Hand brake There is a hand brake on the left and right of the handlebars. Figure 50: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example • The left-hand brake controls the front wheel brake.

  • Page 53: Battery Level Indicator (Battery)

    Description 3.4.6 Battery level indicator (battery) The five LEDs on the battery level indicator show System errors and warnings are displayed by the charge level when the battery is switched on. various light patterns on the battery level indicator. Each LED represents 20% of the charge level. There is a table with all system messages in Section 6.2 System messages.

  • Page 54: Technical Data

    Description Technical data 3.5.1 Pedelec 3.5.4 Emissions The safety requirements as per Electromagnetic Transportation temperature -20… +60 °C Compatibility Directive 2014/30/EU have been met. The pedelec and the charger can be used in Storage temperature -20… +70 °C residential areas without restriction. Operation temperature -10…...

  • Page 55: Fit Fast Charger (36-6/230)

    Description 3.5.6 FIT Fast Charger (36-6/230) Nominal voltage Frequency Battery charge voltage Charging current (max.) Protection class IP40 Operating temperature -5 °C - +40 °C Storage temperature +10 °C - +50 °C Weight 0.3 kg MY22H03 - 32_1.0_04.10.2021...

  • Page 56: Tightening Torques

    Description 3.5.7 Tightening torques Model Tightening torque Screw On-board computer SC-E5003 Attachment screw 0.8 Nm 3 mm hex bit Shifter SHIMANO DEORE SL-M4100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE SL-M5100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE SL-M6100 Attachment screw 3 Nm...
  • Page 57 Description eightpins H01 Seat post axle 8 Nm 6 mm hex bit Slipper clutch 18 Nm 3 mm hex bit Valve cap 0.5 Nm 5 mm hex bit Postpin axle 8 Nm 5 mm hex bit Rear clamping screw (saddle) 8 Nm 3 mm hex bit M5 attachment screw for outer sleeve...

  • Page 58: Transporting And Storing

    Transportation and storage Transporting and storing Weight and dimensions for transportation Weight and dimensions during transportation 21-19-1003 Table 22: Type number, model and pedelec type ** Vehicle weight without battery # Not yet available when the instructions were produced Designated handles, lifting points The box does not have any handles.

  • Page 59: Transportation

    Transporting and storing Transportation 4.3.2 Transporting the pedelec Bicycle rack systems which use the handlebars or CAUTION frame to hold the pedelec in an upside-down position exert inadmissible forces on its components during transportation. This can cause Crash caused by unintentional activation the supporting parts to break.

  • Page 60: Storing

    Transporting and storing Storing  Store pedelec, on-board computer, battery and 4.4.1.1 Preparing a break in operation charger in a clean, dry place where they are  Remove the rechargeable battery from the protected from sunlight. Do not store outdoors pedelec.

  • Page 61: Assembly 5.1 Unpacking

    Assembly Assembly Scope of delivery WARNING  1 pre-assembled pedelec  1 front wheel Risk of eye injury Problems may arise if components are set  2 pedals incorrectly. They may cause serious injuries to  2 quick releases (optional) the face.

  • Page 62: Commissioning

    Assembly Commissioning Only trained specialist staff may perform initial commissioning since initial commissioning of the pedelec requires special tools and specialist knowledge. Experience has shown that a pedelec which has not yet been sold is automatically handed to customers as soon as it appears ready to ride. ...

  • Page 63: Preparing The Wheel

    Assembly 5.3.2 Preparing the wheel There is an arrow on the sides of the tyres with the inscription ROTATION to show the direction of rotation. The inscription says DRIVE on older tyres. The rotation direction arrow indicates the recommended direction of rotation. On road tyres, the direction of rotation is mainly for optical reasons.

  • Page 64: Preparing The Limotec Seat Post

    Assembly 5.3.3 Preparing the LIMOTEC seat post Only applies to pedelecs with this equipment 1 Use the seat height formula to calculate the optimum seat post height for the length of rider's leg: Seat height (SH) = inner leg length (I) × 0.9 2 Lower the seat post further into the seat tube 3 The seat post Bowden cable must be tightened in the frame up to the remote control to the...

  • Page 65: Fitting The Pedals

    Assembly 5.3.4 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.

  • Page 66: Checking The Stem And Handlebars

    Assembly 5.3.5 Checking the stem and handlebars 5.3.5.1 Checking the connections 5.3.5.3 Checking the headset backlash 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.

  • Page 67: Operation

    Operation Operation Risks and hazards WARNING WARNING Injuries and death caused by distraction Injuries and fatalities caused by blind spots A lack of concentration while riding increases the Other road users, trucks, cars and pedestrians risk of an accident. This may cause a crash with often underestimate the speed of pedelecs.
  • Page 68 Operation CAUTION CAUTION Crash caused by material fatigue Crash caused by soiling Intensive use can cause material fatigue. A Heavy soiling can impair pedelec functions, such component may suddenly fail in case of material as braking. This may cause a crash with injuries. fatigue.

  • Page 69: Tips For A Greater Range

    Operation Tips for a greater range The pedelec's range depends on many Gear shift influencing factors. A single battery charge may  Use a low gear and a low level of assistance on only last fewer than 20 kilometres but much more hills and when setting off.

  • Page 70: Error Messages

    Operation Error messages 6.3.1 Battery error message The battery indicates errors with different LED statuses. The LED light patterns are lit ( non-lit ( ) and flashing ( Type Status Lighting pattern Remedy System error Communication error with Check that the charging cable is firmly and properly the pedelec system.

  • Page 71: On-Board Computer Warnings

    Operation On-board computer warnings 6.3.2 Figure 59: Example: Warning W000 Code Cause Limitation Remedy  Contact your specialist dealer. W101 No vehicle speed signal was The maximum speed at which (W011) detected by the speed assistance is provided is lower sensor.

  • Page 72: Error Message Screen

    Operation Error message screen If an error message is shown over the entire display, follow the procedure indicated below to reset the screen. 1 Press the On-Off button (battery). 2 Remove the battery from the mount. 3 Replace the battery. 4 Start the system.

  • Page 73: Instruction And Customer Service

    Operation Instruction and customer service The supplying specialist dealer will provide 6.6.1 Preparing customer service. Contact details can be found on The following tools are required to adjust the the pedelec pass for these operating instructions. pedelec: The specialist dealer will explain all the pedelec functions to the new owner in person, this being when the specialist dealer hands over the pedelec Tape measure...

  • Page 74: Pedelec Adjustment Procedure

    Operation 6.6.2 Pedelec adjustment procedure  Observe the correct order for adjustment. For pedelecs with components only Sequence Adjustment Section order Saddle • Straighten saddle 6.6.4.1 • Adjust saddle height 6.6.4.2 • Adjust saddle position 6.6.4.4 • Adjust saddle tilt 6.6.4.5 Handlebars 6.6.5...

  • Page 75: Determining The Sitting Position

    Operation 6.6.3 Determining the sitting position The starting point for a comfortable posture is the Position on trekking bike Position on sports bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.

  • Page 76: Adjusting The Saddle

    Operation 6.6.4 Adjusting the saddle 6.6.4.1 Straightening the saddle 6.6.4.2 Adjusting the saddle height  To adjust the saddle height safely, either:  Position saddle in direction of travel. In doing • Push the pedelec near to a wall so that the rider so, align the tip of the saddle with the top tube.

  • Page 77: Setting The Saddle Height With The Remote Control

    Operation 5 Open the quick release on the seat post to 6.6.4.3 Setting the saddle height with the remote control change the seat height (1). To do so, push the clamping lever away from the seat post (3). Use the seat height formula to set the saddle height: Seat height (SH) = inner leg length (I) ×...

  • Page 78: Adjusting The Saddle Position

    Operation 6.6.4.4 Adjusting the saddle position 3 Unfasten and adjust the designated screw connections, and clamp them with the The saddle can be shifted on the saddle frame. maximum tightening torque for the saddle The right horizontal position ensures an optimal clamping screws.

  • Page 79: Handlebars

    Operation 6.6.5 Handlebars  Check handlebar width and hand position. The narrower the shoulders are, the greater the bend of the handlebars should be (maximum 28°).  Choose different handlebars if necessary. Contact specialist dealer. Straight handlebars are advisable for sports bikes (e.g.

  • Page 80: Stem

    Operation 6.6.6 Stem 6.6.6.1 Adjusting the handlebar height with Adjusting the quick release clamping force quick release Only applies to pedelecs with this equipment CAUTION 1 Open the stem clamping lever. Crash caused by incorrectly set clamping force Applying excessive clamping force damages the quick release.

  • Page 81: Setting The Quill Stem

    Operation 6.6.6.2 Setting the quill stem 6.6.6.3 Adjusting the Ahead stem Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment In the case of a quill stem, the stem and fork In the case of an Ahead stem, the stem is placed steerer form a permanently interconnected directly on the fork steerer, which protrudes over component, which is clamped in the fork steerer.

  • Page 82: Adjusting The Angle-Adjustable Stem

    Operation 6.6.6.4 Adjusting the angle-adjustable stem Only applies to pedelecs with this equipment Angle-adjustable stems are available in different lengths for quill and Ahead stems. Figure 76: Different versions of angle-adjustable stems Adjusting the stem angle (c) changes both the distance from the upper body to the handlebars (b) and the handlebar height (a).

  • Page 83: Ergonomic Handles

    Operation 6.6.7 Ergonomic handles In the case of ergonomically shaped handles, the palm rests on the anatomically shaped handle. A greater contact surface means that the pressure is more evenly distributed. Nerves and vessels are no longer squeezed in the carpal tunnel. Figure 78: Correct (1) and incorrect (2) position of the handle 1 Undo the handle screw.

  • Page 84: Tyres

    Operation 6.6.8 Tyres It is not possible to offer a general recommended Tyre pressure in bar for body tyre pressure for a particular pedelec or tyre. The weight correct tyre pressure largely depends on the Tyre width about about about weight load on the tyres, mainly determined by 60 kg 80 kg...

  • Page 85: Brake

    Operation 6.6.9 Brake The brake lever grip distance can be adjusted to 6.6.9.2 Brake handle tilt angle ensure that it can be reached more easily. The The nerves that pass through the carpal tunnel pressure point can also be adjusted to the rider's are connected to the thumb and the index and preferences.

  • Page 86: Determining The Grip Distance

    Operation 2 Set the brake lever angle as indicated in the table. 20 – 25° > 10 cm 25 – 30° 0 – 10 cm 30 – 35° 0 – 10 cm 35 – 45° > 10 cm Saddle-handlebar height Brake angle difference (mm) >10...

  • Page 87: Grip Distance On A Shimano St-Ef41 Brake Lever

    Operation 6.6.9.4 Grip distance on a SHIMANO ST-EF41 brake lever Only applies to pedelecs with brakes: BL-M4100 BL-M7100 BL-M8100 BL-MT200 BL-MT201 BL-MT400 BL-MT401 BL-MT402 BL-T6000 GRX ST-RX600 M7100 M8100 RS785 The brake lever position can be adjusted to the rider's requirements. Contact your specialist dealer.

  • Page 88: Retracting The Brake Linings

    Operation 6.6.9.5 Retracting the brake linings Disc brakes require wearing-in time. The braking force increases over time. The braking force is increased during break-in time. This is also the case when the brake pads or brake discs are replaced. 1 Accelerate pedelec to 25 km/h. 2 Brake pedelec until it comes to a halt.

  • Page 89: Gear Shift

    Operation 6.6.10 Gear shift Adjust the position of the gear shift to the rider’s 2 Place control panel or shifter into the position needs. where the rider can use the control panel or the shifter with their thumb and/or index finger. 1 Undo attachment screw.

  • Page 90: Suspension

    Operation 6.6.11 Suspension A pedelec’s fork suspension and rear frame  Follow the the correct order for adjustment. damper suspension can be adjusted to the rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Rear frame Sequence Adjustment...

  • Page 91: Adjusting The Rockshox Fork Coil Spring With Spacer For Pre-Tensioning

    Operation 6.6.12.1 Adjusting the ROCKSHOX fork coil spring with spacer for pre-tensioning Only applies to pedelecs with this equipment 1 Put on normal cycling clothing (including 7 Check the sag. baggage). Setting 2 Ask someone to hold the pedelec. Prohibited >30% 3 Stand on the pedals.
  • Page 92 Operation Adjusting preload internally  Only your specialist dealer may make an internal adjustment to the preload. Preload spacers compress or decompress the spring without changing deflection. Figure 89: Screwing and unscrewing the preload adjustment ring The coil spring can be preloaded with the maximum number of preload spacers specified for the fork model in question.

  • Page 93: Adjusting The Rockshox Coil Spring With An External Preload Adjuster

    Operation 6.6.12.2 Adjusting the RockShox coil spring with an external preload adjuster Only applies to pedelecs with this equipment 1 Turn the preload adjustment ring anti- 6 Note distance between dust wiper and the O- clockwise until it locks into position ring.

  • Page 94: Rockshox Paragon Silver Coil Spring

    Operation 6.6.12.3 ROCKSHOX Paragon Silver coil spring Only applies to pedelecs with this equipment 1 Put on your normal cycling clothing, including 5 Check the sag. baggage. Ask someone to hold the bicycle. Setting Stand on the pedals while wearing cycling clothing.
  • Page 95 Operation 7 Take off the cover cap to remove or reposition the preload spacer.  On a new vehicle, the 5-mm preload position of the preload spacer is positioned as standard (1). Figure 97: Screwing and unscrewing the preload adjustment ring ...

  • Page 96: Adjusting The Rockshox Fork Air Suspension

    Operation 6.6.12.4 Adjusting the RockShox fork air suspension Only applies to pedelecs with this equipment  The pressure should be measured at an ambient Body weight ROCKSHOX LYRIK SELECT temperature of 21 °C to 24 °C. 1 Place all dampers in the open position before adjusting the sag.
  • Page 97 Operation 10 Get off the pedelec without allowing it to de- flect. Measure or read the distance between the dust wiper and the O-ring end or cable tie. This measurement is the sag. The recom- mended sag is between 10% and 20% (hard) or 20% to 30% (soft).

  • Page 98: Adjust The Rear Frame Damper Sag

    Operation 6.6.13 Adjust the rear frame damper sag Settings on the chassis change ride performance significantly. The rider needs to get used to the pedelec and break it in to prevent accidents. Greater sag (20%–30%) A greater sag increases sensitivity to bumps, thus producing greater suspension motion.

  • Page 99: Adjusting The Rockshox Rear Frame Damper

    Operation 6.6.13.1 Adjusting the RockShox rear frame damper Only applies to pedelecs with this equipment  The fork sag is adjusted. Weight Air pressure  When adjusting the sag, ensure that all dampers Pound per are in the open position, i.e. turned anti-clockwise Kilogram Pound (lbs) square inch...
  • Page 100 Operation 11 Read the sag value on the scale. The optimum sag percentage is 25%. The sag level may be adjusted by ± 5%, depending on the rider's preferences (20% to 30%). 12 The air pressure must be adjusted if the sag level is not reached.

  • Page 101: Fork Rebound Damping

    Operation 6.6.14 Fork rebound damping Only applies to pedelecs with this equipment Rebound damping in the suspension fork and the Rebound damping needs to be increased to rear frame damper determines the speed at which achieve an optimal setting if the air pressure or the rear frame damper rebounds after being spring stiffness are increased.

  • Page 102: Adjusting The Rockshox Suspension Fork

    Operation 6.6.14.1 Adjusting the RockShox suspension fork Only applies to pedelecs with this equipment Figure 106: Adjusting the RockShox rebound  The fork sag is adjusted.  Turn the rebound screw clockwise damper towards the tortoise symbol.  The rebound speed is decreased (slower return).

  • Page 103: Adjusting The Rear Frame Damper Rebound Damper

    Operation 6.6.15 Adjusting the rear frame damper rebound damper Only applies to pedelecs with this equipment The rear frame damper rebounds at a controlled frame damper rebounds in a controlled way, so speed if it is optimally adjusted. The rear wheel that the rider remains sitting in a horizontal does not bounce off rough surfaces or the ground;...

  • Page 104: Adjusting The Rockshox Rear Frame Damper

    Operation 6.6.15.1 Adjusting the RockShox rear frame damper Only applies to pedelecs with this equipment Figure 108: Position and shape of the rebound adjuster (red) depends on the model  The sag in the rear frame damper is adjusted.  Turn rebound adjuster clockwise. ...

  • Page 105: Compression Adjuster On Rear Frame Damper

    Operation 6.6.16 Compression adjuster on rear frame damper When optimally adjusted, the rear frame damper deflects quickly and unhindered when the bike hits bumps and absorbs a bump. Traction is retained (blue line). The saddle rises slightly when absorbing a bump (green line). Compression adjuster set to hard Compression adjuster set to soft •...

  • Page 106: Adjusting The Rockshox Compression Adjuster

    Operation 6.6.16.1 Adjusting the RockShox compression adjuster Only applies to pedelecs with this equipment Figure 110: Position and shape of the compression adjuster (blue) depends on the model 1 Set the compression adjuster to the middle position. 2 Ride the pedelec over a small obstacle. ...

  • Page 107: Lighting

    Operation 6.6.17 Lighting Example 1 If the front light is positioned too high, oncoming traffic will be dazzled. This can cause a serious accident with fatalities. Example 2 Positioning the front light correctly can ensure that oncoming traffic is not dazzled and no-one is put at risk. Example 3 If the front light is positioned too low, the space ahead is not illuminated to an optimum extent and the rider's vision is reduced in the dark.

  • Page 108: Light

    Operation 4 Place pedelec 5 m from the wall. 6 Switch on riding light. 5 Stand the pedelec up straight. Hold the handlebars straight with both hands. Do not use the kickstand. Figure 113: Light positioned too high (1), correctly (2) and too low (3) 7 Check the position of the light beam.

  • Page 109: Adjust On-Board Computer

    Operation 6.6.18 Adjust on-board computer 3-switch control panel CAUTION Crash caused by distraction 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 on-board computer.

  • Page 110: Opening The Settings Menu

    Operation MTB control panel Control panel on the right side of the handlebars Switch Function W HE N R ID IN G Change up Change down Switch between automatic and manual Gear shift Control panel on the left side of the handlebars Figure 117: MTB control panel Switch...

  • Page 111: Closing The Settings Menu

    Operation 3 Press switch X or switch Y until the desired Settings menu structure language is highlighted. → CL EAR Clears the settings 4 Press the button (display) or switch A. → CL O CK Adjusting the clock  The language has been changed. The settings →...

  • Page 112: Adjusting The Clock

    Operation  There are two selection options: 6.6.20.5 Changing the brightness Display Function  The settings menu is opened. Increase value Increases the displayed speed value. 1 Press switch X or switch Y until Reduce value Reduces the displayed speed value. B R I G H T N E S S is highlighted.

  • Page 113: Automatic Light Setting

    Operation 6.6.20.7 Automatic light setting *3 Your specialist dealer can adjust a start gear up to the maximum gear level on the gear shift  The settings menu is opened. mounted on the pedelec. 1 Press switch X or switch Y until S T A R T 3 Press switch X or switch Y until the desired M O D E is highlighted.

  • Page 114: Adjusts The Gear Shift

    Operation 6.6.20.10Adjusts the gear shift 6.6.20.11RD protection reset Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment   It is only possible to adjust the gear shift if using It is only possible to perform the RD protection an electronic gear shift.

  • Page 115: Deleting All Saved Values

    Operation 6.6.21 Connecting an external device 6.6.20.12Deleting all saved values The saved DST value (distance travelled) can be 6.6.21.1 Connecting device via the ANT cleared together with TIME (trip time), AVG 1 Switch on the drive system. (average speed) and MAX (maximum speed). There are two ways to do this.

  • Page 116: Connect External Devices

    Operation Connect external devices Using E-TUBE PROJECT E-TUBE PROJECT is required to change drive Notice system settings and update firmware. The functions that can be configured differ  Do not establish connection to external depending on the pedelec. You will find details in devices if the battery is charging.

  • Page 117: Accessories

    Operation Accessories We recommend a parking stand into which either the front wheel or rear wheel can be inserted CAUTION securely for pedelecs which do not have a kickstand. The following accessories are Risk of crushing due to exposed springs recommended: The child may crush his/her fingers on exposed Description...

  • Page 118: Trailer

    Operation 6.9.2 Trailer 6.9.2.1 Approval for trailer with Enviolo hub Only applies to pedelecs with this equipment CAUTION Only compatible bicycle trailers are approved for ENVIOLO hub gears. Crash caused by brake failure KETTLER The braking distance may be longer if the trailer is carrying excessive load.

  • Page 119: Approval For Trailer With Rohloff Hub

    Operation 6.9.4 Tubeless and airless tyres 6.9.2.2 Approval for trailer with ROHLOFF hub Only applies to pedelecs with this equipment Bicycle riding without tubes reduces the risk of tyre punctures or even avoids them completely. ROHLOFF Speedhub 500/14 The specialist dealer will advise on choosing a As a basic rule, it is permitted to use a trailer suitable tyre system for the pedelec.

  • Page 120: Personal Protective Equipment And Accessories For Road Safety

    Operation 6.10 Personal protective equipment and accessories for road safety Seeing and being seen is crucial in road traffic. 7 The two separate brakes on the pedelec must The following requirements must be met for riding work at all times. a road-safe vehicle on public roads.

  • Page 121: Straightening The Quickly Adjustable Stem

    Operation 6.12 Straightening the quickly 6.13 Using the pannier rack adjustable stem CAUTION Only applies to pedelecs with this equipment 1 Open stem clamping lever. Crash caused by loaded pannier rack The pedelec is handled differently with a loaded pannier rack, in particular when the rider needs to steer and brake.

  • Page 122: Raising The Kickstand

    Operation 6.16 Using the pedals  The ball of the foot is placed on the pedal when riding and pedalling. Figure 131: The maximum load bearing (1) capacity is indicated on the pannier rack.  Never exceed the maximum permitted total weight when packing the pannier.

  • Page 123: Rechargeable Battery

    Operation 6.19 Rechargeable battery  Switch off the battery and the drive system before 6.19.0.2 Inserting the battery removing or inserting the battery. 6.19.0.1 Removing the battery Figure 134: Inserting the battery 1 Place the battery into the battery lower mount with the contacts facing the front (1).

  • Page 124: Charging The Battery

    Operation 6.19.1 Charging the battery  The ambient temperature during the charging process must be within the range from 0 °C to 40 °C.  The battery can remain on the pedelec or can be removed for charging.  Interrupting the charging process does not damage the battery.

  • Page 125: Using Pedelec With The Electric Drive System

    Operation 6.20 Using pedelec with the electric drive system 6.20.1 Switching on the electric drive 6.20.2 Switching off the electric drive system system The system switches off automatically ten minutes after the last command. CAUTION The drive system can also be switched off on the Crash caused by lack of readiness for braking battery.

  • Page 126: Using The On-Board Computer

    Operation 6.21 Using the on-board computer 3-switch control panel CAUTION Crash caused by distraction 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 on-board computer.

  • Page 127: Using The Riding Light

    Operation MTB control panel The on-board computer has one button (1) and a display screen (2). Figure 138: MTB control panel Figure 139: SC-EM800 on-board computer details Switch Y Switch X Switch Function Control panel on the right side of the W HE N R ID IN G handlebars BUT T O N...

  • Page 128: Using The Push Assist System

    Operation 6.21.4 Switching the journey information 6.21.3 Using the push assist system The displayed journey information can be CAUTION switched. Injury caused by pedals The pedals turn when using the push assist due to the system design.  You must steer the pedelec securely with both Figure 140: Changing from main display screen to DST hands when using push assist.

  • Page 129: Brake

    Operation 6.22 Brake 6.22.1 Using the brake lever WARNING Crash caused by brake failure 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 130: Suspension And Damping

    Operation 6.23 Suspension and damping Compression adjuster set to hard Compression adjuster set to soft • Causes the suspension fork to move higher within • Causes the fork to deflect quickly and easily. This the deflection range. This improves efficiency, makes it easier to maintain speed and maintains momentum and makes it easier to ride momentum when riding over uneven rugged...

  • Page 131: Adjusting The Rockshox Compression Adjuster

    Operation 6.23.0.1 Adjusting the RockShox compression adjuster  Turn compression adjuster clockwise.  The damping and compression hardness is increased and the deflection stroke speed is reduced. Efficiency on hilly and flat terrain is improved. Figure 143: Changing compression adjuster to a harder setting ...

  • Page 132: Gear Shift

    Operation 6.24 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. ...

  • Page 133: Parking

    Operation 6.25 Parking 6 Remove the on-board computer (see Notice Section 6.18.1.1), battery (see Section 6.16.1.1, 6.16.2.1 or 6.16.3.1) and mobile phone to Heat or direct sunlight can cause the tyre pressure protect against theft. to increase above the permitted maximum 7 Clean and service pedelec after every ride;...
  • Page 134 Operation 2 Pull handlebars into highest possible position. Figure 147: All Up pulled into highest possible position 3 Turn handlebars 90° in a clockwise direction. Figure 148: All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever. MY22H03 - 32_1.0_04.10.2021...

  • Page 135: Cleaning, Servicing And Maintenance

    Cleaning, servicing and maintenance Cleaning, servicing and maintenance  Clean, service and maintain pedelec as indicated on check list. Complying with these measures is the only way to reduce wear on components, increase the operating hours and guarantee safety. Check list before each ride Check list for weekly tasks Check everything is sufficiently Clean chain...
  • Page 136 Cleaning, servicing and maintenance Check list for monthly tasks Check list for monthly tasks   Cleaning the battery Section 7.3.2 Clean hub Section 7.3.12   Clean control panel Section 7.3.1 Cleaning the frame Section 7.3.4   Clean on-board computer Section 7.3.1 Clean tyres Section 7.3.10...
  • Page 137 Cleaning, servicing and maintenance Check list for tasks to do every six months (or every 1,000 Check list for tasks to do every six months (or every 1,000 Check Bowden cables gear  Check steering headset Section 8.5.6  Section 7.5.10.2 shift ...
  • Page 138 Cleaning, servicing and maintenance CAUTION WARNING Crash and falling caused by unintentional Crash caused by brake failure activation Oil or lubricant on the brake disc in a disc brake There is a risk of injury if the drive system is or on the rim of a rim brake can cause the brake activated unintentionally.

  • Page 139: Before Each Ride

    Cleaning and servicing Before each ride Complying with these cleaning instructions is the 7.1.5 Checking the pannier rack only way to reduce wear on components, increase 1 Hold onto pedelec by its frame. Hold onto the operating hours and guarantee safety. pannier rack with the other hand.

  • Page 140: Checking The Bell

    Cleaning and servicing 7.1.10 Checking the bell 1 Press the bell button downwards. 2 Let button spring back.  If you do not hear a clear, distinct ring of the bell, replace bell. Contact specialist dealer. 7.1.11 Checking the handles ...

  • Page 141: After Each Ride

    Cleaning and servicing After each ride Complying with these cleaning instructions is the 7.2.5 Cleaning the brake only way to reduce wear on components, increase the operating hours and guarantee safety. The following items should be ready for use to ...

  • Page 142: Basic Cleaning

    Cleaning and servicing Basic cleaning Complying with these basic cleaning instructions 7.3.2 Rechargeable battery is the only way to reduce wear on components, increase the operating hours and guarantee safety. The following are required for basic cleaning: CAUTION Tool Cleaning agent Risk of fire and explosion due to penetration by water The battery is only protected from simple spray...

  • Page 143: Frame, Fork, Pannier Rack, Guards And Kickstand

    Cleaning and servicing 7.3.4 Frame, fork, pannier rack, guards 7.3.7.1 Leather handles and kickstand Leather is a natural product and has similar properties to human skin. Regular cleaning and care help to prevent leather dehydrating, fading or becoming brittle or stained. 1 Soak the components with dish-washing detergent if the dirt is thick and ingrained.

  • Page 144: Leather Saddle

    Cleaning and servicing 7.3.9.1 Leather saddle 7.3.12 Hub Leather is a natural product and has similar 1 Put on protective gloves. properties to human skin. Regular cleaning and 2 Remove dirt from hub with a sponge and soapy care help to prevent leather dehydrating, fading or water.

  • Page 145: Brake

    Cleaning and servicing 7.3.15 Brake 7.3.18 Chain 7.3.15.1 Brake lever Notice  Carefully clean the brake levers with a damp, soft cloth.  Never use aggressive (acid-based) cleaners, rust removers or degreasers when cleaning 7.3.16 Brake disc the chain.  Never use gun oil or rust remover spray. ...

  • Page 146: Servicing

    Cleaning and servicing Servicing Complying with these servicing instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Battery terminal grease Table 53: Required tools and cleaning agents for servicing 7.4.1 Frame Notice Figure 149: Diagram showing wear, operating hours (x) ...

  • Page 147: Pannier Rack

    Cleaning and servicing 7.4.3 Pannier rack 4 If you have a Speedlifter Twist, also apply oil to the unlocking bolt groove in the Speedlifter body. 5 Apply a little acid-free lubricant grease between the stem quick release lever and the 1 Dry pannier rack with a cloth.

  • Page 148: Seat Post

    Cleaning and servicing 7.4.9 Seat post 7.4.11 Leather saddle 1 Carefully preserve screw connections with wax spray. In doing so, ensure that no wax is applied to the metal contact surfaces. Standard leather care products keep leather 2 Replace the assembly paste protective layer smooth and resistant, brighten its appearance and on the metal contact surfaces on the seat post improve or replace stain protection.

  • Page 149: Gear Shift

    Cleaning and servicing 7.4.14 Gear shift 7.4.16 Caring for the chain 7.4.14.1 Rear derailleur articulated shafts and jockey wheels  Place newspaper or paper towels underneath to collect chain oil. 1 Lift rear wheel.  Treat front and rear derailleur articulated 2 Turn the crank briskly in an anti-clockwise shafts and jockey wheels with Teflon spray.

  • Page 150: Caring For The Chain And All-Round Chain Guard

    Cleaning and servicing 7.4.18 Caring for the brake 7.4.16.1 Caring for the chain and all-round chain guard 7.4.18.1 Caring for the brake  Place newspaper or paper towels underneath to collect chain oil. Notice 1 Lift rear wheel. 2 Turn the crank briskly in an anti-clockwise ...

  • Page 151: Maintenance

    Cleaning and servicing Maintenance The following tools are required for maintenance: 7.5.1.1 Checking the tyre pressure Notice Gloves If the tyre pressure is too low in the tyre, the tyre does not achieve its load bearing capacity. The Ring spanners 8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm tyre is not stable and may come off the rim.
  • Page 152 Cleaning and servicing Dunlop valve 6 Screw the rim nut gently against the rim with the tips of your fingers. Only applies to pedelecs with this equipment  Correct tyre pressure if necessary (see The tyre pressure cannot be measured on the Section 6.6.8).

  • Page 153: Checking The Tyres

    Cleaning and servicing 7.5.1.2 Checking the tyres The tread is far less important for bicycle tyres 2 Check the side walls for wear. If there are any than it is for car tyres, for example. Consequently, cracks or tears, the tyre must be replaced. tyres can still be used with a worn tread with the exception of tyres on mountain bikes.

  • Page 154: Checking The Rims

    Cleaning and servicing 7.5.1.3 Checking the rims 7.5.1.5 Checking the nipple well The nipple holes can weaken the tyre bed. WARNING  Check to see if cracks are emerging from the nipple holes. Crash caused by a worn rim  If there are cracks radiating from the nipple A worn rim can break and block the wheel.

  • Page 155: Checking The Brake System

    Cleaning and servicing 7.5.2 Checking the brake system 7.5.2.2 Checking the hydraulic system CAUTION 1 Push the brake lever and check whether any brake fluid leaks out of the lines, connections or on the brake linings. Crash caused by brake failure Worn brake discs and brake linings and a lack of ...

  • Page 156: Checking The Disc Brake

    Cleaning and servicing 7.5.2.4 Checking the disc brake Only applies to pedelecs with this equipment Checking the brake linings Checking the brake discs   Check that the brake linings are no less than Put on gloves as the brake disc is very sharp. 1.8 mm wide at any point and there are no less 1 Take hold of brake disc and joggle it gently to than 2.5 mm between the brake lining and...

  • Page 157: Checking The Lighting

    Cleaning and servicing 7.5.3 Checking the lighting 1 Check the cable connections on the front and  If the front or rear lights do not come on, take pedelec out of service. Contact specialist rear lights for damage and corrosion and dealer.

  • Page 158: Checking The Stem

    Cleaning and servicing 7.5.4 Checking the stem 7.5.7 Checking the seat post  The stem and quick release system must be 1 Take seat post out of the frame. inspected at regular intervals. The specialist 2 Check seat post for cracks and corrosion. dealer should adjust them if they require 3 Reinsert seat post.

  • Page 159: Checking The Derailleur Gears

    Cleaning and servicing 7.5.10 Checking the gear shift 7.5.9.1 Checking the derailleur gears The chain is tensioned by the rear derailleur in 1 Check whether all gear shift components are pedelecs with derailleur gears. free of damage. 1 Place the pedelec on stand. 2 Contact your specialist dealer if components are damaged.

  • Page 160: Adjusting Gear Shift

    Cleaning and servicing 7.5.11 Adjusting gear shift 7.5.12 Bowden-cable-operated gear shift, single-cable 7.5.11.1 ROHLOFF hub Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment  Adjust the play on the adjusting sleeves on the 1 Check whether the shift cable tension is set in shifter housing to ensure a smooth gear shift.

  • Page 161: Bowden-Cable-Operated Twist Grip, Dual-Cable

    Cleaning and servicing 7.5.14 Bowden-cable-operated twist grip, 7.5.15 Checking kickstand stability dual-cable 1 Place the pedelec on a slight elevation of 5 cm. Only applies to pedelecs with this equipment 2 Extend kickstand.  For a smooth gear shift, set the adjusting 3 Jolt pedelec to check stability.

  • Page 162: Maintenance

    Maintenance Maintenance Initial inspection Component-specific maintenance tasks After 200 km or 4 weeks after purchase High-quality components require extra maintenance. Maintenance tasks require Vibrations produced while riding can cause technical expertise, special tools and special screws and springs that were tightened during lubricants.
  • Page 163 Maintenance Suspension fork maintenance intervals Maintenance intervals for suspension seat post Suntour suspension fork by.schulz suspension seat post  Maintenance 1 Every 50 hours Maintenance After the first 250 km; every  1,500 km after  Maintenance 2 Every 100 hours that FOX suspension fork Suntour suspension seat post...
  • Page 164 Maintenance Maintenance intervals for rear frame damper Maintenance intervals for hub RockShox rear frame damper SHIMANO 11-speed hub  Service air chamber assembly Every 50 hours Internal oil change and maintenance 1,000 km after start of use,then  every 2 years or ...

  • Page 165: Carry Out Initial Inspection

    Maintenance CAUTION WARNING Hazard for the environment due to toxic Injury due to damaged brakes substances Special tools and specialist knowledge are The brake system contains toxic and required to repair the brakes. Incorrect or environmentally harmful oils and lubricants. Such unauthorised assembly can damage the brakes.

  • Page 166: Maintenance Instructions

    Maintenance Maintenance instructions Complying with these maintenance instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Diagnosis and documentation of current status Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection...
  • Page 167 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.7 O.K. Dirt Cleaning month Once a Care for Section 7.4.8 … O.K. Untreated Talcum powder month Handles before Wear; check if Section 7.1.11 …...
  • Page 168 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months … Section 7.4.10 O.K. Untreated 6 months Wear Section 7.5.1.3 … O.K. Defective rim New rim as specified Rims in the parts list once a Wear on brake Section 7.5.2.6...
  • Page 169 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.8 O.K. Dirt Cleaning month 6 months Care for … O.K. Untreated Leather wax Seat post 6 months Complete clean, …...
  • Page 170 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Venting … See manufac- O.K. hours turer Cleaning … See manufac- O.K. hours turer Venting … See manufac- O.K. RockShox hours turer suspension seat post Complete mainte- …...
  • Page 171 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Drive/gear shift Chain/ 6 months Check for damage Check for … O.K. Damage Refasten if necessary cassette/ damage or replace as speci- pinion/chain- fied in parts list ring Chain guard/ 6 months...
  • Page 172 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Miscellaneous before Stability Section 7.1.5 … O.K. Loose Firm each ride Once a Dirt … Section 7.3.4 O.K. Dirt Cleaning month Pannier rack 6 months Servicing …...

  • Page 173: Servicing The Frame

    Maintenance 8.5.1 Servicing the frame 8.5.3 Servicing axle with quick release 1 Check frame for cracks, warping and damage to the paintwork. CAUTION  If there are any cracks, warping or damage to the paintwork, remove the pedelec from Crash caused by unfastened quick service.

  • Page 174: Maintaining The Stem

    Maintenance  The quick release lever is flush with the lower 8.5.4 Maintaining the stem housing. Incorrectly fastened screws may come loose due  You should be able to see slight impression on to impact. The stem may no longer be firmly fixed the palm of your hand when you close the quick in its position as a result.

  • Page 175: Servicing The Steering Headset

    Maintenance 8.5.6 Servicing the steering headset 8.5.7 Servicing the fork 1 Remove fork. Only applies to pedelecs with this equipment 2 Clean steering headset. If it is very dirty, flush WARNING the bearing with cleaning agents such as WD- 40 or Karamba. Injury due to explosion 3 Check steering headset for damage.

  • Page 176: Servicing The Carbon Suspension Fork

    Maintenance 8.5.7.1 Servicing the carbon suspension fork 8.5.7.2 Servicing the suspension fork 1 Remove fork. 1 Remove fork. 2 Check fork for cracks, warping and damage to 2 Check fork for cracks, warping and damage to the paintwork. the paintwork. ...

  • Page 177: Servicing Seat Post

    Maintenance 8.5.8 Servicing seat post 8.5.8.1 Servicing the carbon seat post Only applies to pedelecs with this equipment WARNING You need to distinguish between scratches on the paintwork and impacts if the carbon seat post Intoxication from lubrication oil paintwork is damaged. The lubrication oil for eightpins seat posts is toxic ...

  • Page 178: By.schulz Suspension Seat Post

    Maintenance 8.5.8.2 by.schulz suspension seat post 8.5.8.3 Suntour suspension seat post Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment 1 Remove seat post from the frame. 1 Remove seat post from the frame. 2 Remove safety and protective cover. 2 Remove safety and protective cover.

  • Page 179: Eightpins Ngs2 Seat Post

    Maintenance 8.5.8.4 eightpins NGS2 seat post Only applies to pedelecs with this equipment Removing the seat post 5 Pull cartridge from the piston rod while pushing the outer sleeve into the frame at the same 1 Use a 2.5 mm hex key to turn the height time to help.
  • Page 180 Maintenance 9 Pull out the outer sleeve end cap from the Caring for the outer sleeve counter support on the Postpin interface on the 1 Detach spring washer or outer sealing ring. seat post. Figure 175: Removed spring washer Figure 173: Pulling the end cap out 2 Carefully remove the wiper from the groove.
  • Page 181 Maintenance 8 Carefully re-insert dry felt ring with one end in Increasing the air pressure the designated groove. 1 Use 3 mm hex spanner to unscrew valve cap. 9 Unfurl felt ring within the outer sleeve, so that it lies on the groove. 10 Carefully press felt ring into the groove by hand.
  • Page 182 Maintenance 5 Use a 3 mm hex spanner to screw the valve lid 3 Set the torque to 18 Nm with a torque wrench back on and tighten with a maximum of 0.5 Nm. and a 6 mm hex bit with a shaft length of at least 25 mm.
  • Page 183 Maintenance installing the outer sleeve and slide bushing Notice 1 Carefully push slide bushing tube into the seat tube.  Never pull Bowden cable forwards at an angle. 2 Press outer sleeve downwards with your hand. 4 Carefully push cartridge into the seat tube. Pull 3 Use a 3 mm hex spanner to fasten the the Bowden cable out of the frame to help.
  • Page 184 Maintenance 9 Carefully insert slide bushing tube into the seat tube. Figure 200: Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper. Figure 197: Inserting the slide bushing tube into the seat tube 10 Place outer sleeve on the seat tube and push downwards firmly.

  • Page 185: Eightpins H01 Seat Post

    Maintenance 8.5.8.5 eightpins H01 seat post Only applies to pedelecs with this equipment Removing the seat post Removing the outer sleeve and slide bushing 1 Use a 5 mm hex spanner to unscrew the 1 Use a 3 mm hex spanner to remove Postpin axle.
  • Page 186 Maintenance 4 Carefully remove the wiper from the groove. 13 Insert cleaned or new wiper in the upper groove. 14 Stretch spring washer over the wiper. Figure 211: Removing the wiper Figure 215: inserting and fastening the wiper 5 Use a small, sharp object to look for and remove the end of the felt ring.
  • Page 187 Maintenance Clean slide bushing 3 Clean the seat post longitudinal grooves with a damp cloth. 1 Clean the slide bushing tube with a damp cloth. Figure 216: Cleaning the slide bushing tube Figure 219: Cleaning the longitudinal groove Notice 4 Apply grease into the longitudinal groove and on both cross-pieces.
  • Page 188 Maintenance installing the outer sleeve and slide bushing 5 Look at the frame interface through the hole in the Postpin. Push the seat post down until the 1 Carefully push slide bushing tube into the seat Postpin mounting interface on the seat post tube.

  • Page 189: Rear Frame Damper

    Maintenance 8.5.9 Rear frame damper Only applies to pedelecs with this equipment CAUTION WARNING Hazard for the environment due to toxic Injury due to explosion substances The air chamber is pressurised. If the air system The rear frame damper contains toxic and is serviced in a rear frame damper, it can explode environmentally harmful oils and lubricants.

  • Page 190: Fox Component-Specific Maintenance

    Maintenance 8.5.9.1 FOX component-specific maintenance FOX Service must perform maintenance on suspension forks, rear frame dampers and suspension seat posts.  Maintenance includes a complete inspection of interiors/exteriors.  All dampers are reconditioned.  The airtight seals are replaced in air suspension forks.

  • Page 191: Troubleshooting, Fault Clearance And Repair

    Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Troubleshooting and fault 9.1.2 RD protection reset clearance The rear derailleur protection function will immediately trigger to protect the system if the The components of the drive system are checked pedelec is exposed to a strong impact –...

  • Page 192: Assistance Function

    Troubleshooting, fault clearance and repair Assistance function Symptom Cause Remedy Check battery charge level. Is the battery charged sufficiently? Recharge the battery if it is almost flat. Does the rider ride up long inclines in Switch off the drive system. summer weather or with a heavy load for a Wait a moment and then check again.

  • Page 193: Rechargeable Battery

    Troubleshooting, fault clearance and repair Rechargeable battery Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace battery with new one. quickly. service life. All five battery indicators are The drive unit firmware version may not be ...

  • Page 194: Lighting

    Troubleshooting, fault clearance and repair Symptom Cause Remedy The battery cannot be  Contact your specialist dealer. inserted. Fluid is leaking from the  Observe all the warnings in Section 2 Safety. battery. There is an unusual smell. Remove the battery from the pedelec immediately. Contact the fire service.

  • Page 195: Miscellaneous

    Troubleshooting, fault clearance and repair Miscellaneous Symptom Cause Remedy Two beeps will sound if a Pressed switch mode has been switch is pressed but the This is not a malfunction. deactivated. switch cannot be operated.  This occurs when a warning or an error is shown on the Three beeps are sounded.

  • Page 196: Rockshox Suspension Fork

    Troubleshooting, fault clearance and repair 9.5.1 RockShox suspension fork 9.5.1.1 Rebound too fast The suspension fork rebounds too quickly, Fork head and handlebars are deflected upwards producing a "pogo stick" effect, where the wheel if the wheel bounces back from the ground. Body lifts from the ground in an uncontrolled way.

  • Page 197: Rebounding Too Slowly

    Troubleshooting, fault clearance and repair 9.5.1.2 Rebounding too slowly The fork does not rebound quickly enough after The fork remains in a deflected state, causing the absorbing a bump. The fork also remains headset and handlebars to move to a lower deflected over subsequent bumps, which reduces position.

  • Page 198: Suspension Too Soft On Inclines

    Troubleshooting, fault clearance and repair 9.5.1.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. The shifts forward and the pedelec loses some deflection is quickly used up, the rider's weight momentum. Figure 232: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 233: Changing compression adjuster to a harder setting...

  • Page 199: Excessively Hard Damping On Bumps

    Troubleshooting, fault clearance and repair 9.5.1.4 Excessively hard damping on bumps When the bike hits a bump, the fork deflects too The headset and handlebars are deflected slowly and the wheel lifts up from the bump. upwards significantly, which can impair control. Traction decreases when the wheel no longer touches the ground.

  • Page 200: Rockshox Rear Frame Damper

    Troubleshooting, fault clearance and repair 9.5.2 RockShox rear frame damper 9.5.2.1 Rebound too fast The rear frame damper rebounds too quickly, Saddle and handlebars are deflected upwards producing a “pogo stick” effect or causing the bike when the wheel bounces back from the ground. to bounce after the wheel hits a bump and lands The rider's body weight may be shifted upwards on the ground again.

  • Page 201: Rebounding Too Slowly

    Troubleshooting, fault clearance and repair 9.5.2.2 Rebounding too slowly The rear frame damper does not rebound quickly The rear frame damper remains in a deflected enough after a bump has been compensated and state after contact with the first bump. When the is not in the required initial position when the rear wheel hits the second bump, the saddle wheel hits the next bump.

  • Page 202: Suspension Too Soft On Inclines

    Troubleshooting, fault clearance and repair 9.5.2.3 Suspension too soft on inclines The rear frame damper deflects deeply through the rider's weight shifts forward and the pedelec the deflection range. Deflection is quickly used up, loses some momentum. Figure 240: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 241: Position and shape of the compression adjuster (blue) depends on the model ...

  • Page 203: Excessively Hard Damping On Bumps

    Troubleshooting, fault clearance and repair 9.5.2.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and rider are deflected upwards and too slowly and the rear wheel lifts up from the forwards, the rear wheel loses contact with the bump.

  • Page 204: Repair

    Troubleshooting, fault clearance and repair Repair Special expertise and tools are required for many 9.6.4 Checking tyre clearance repairs. For this reason, repairs may only be The tyre needs to be checked each time a carried out at a specialist dealer. These include: suspension fork tyre is changed to another size.

  • Page 205: Recycling And Disposal

    Recycling and disposal Recycling and disposal This device is marked according to the recycling saves reserves of raw materials and European Directive 2012/19/EU on ensures that all the regulations for protection of waste electrical and electronic health and the environment are adhered to when equipment –...
  • Page 206 Recycling and disposal Waste type Disposal Dispose of Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Biodegradable cleaning cloths daubed in oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer...

  • Page 207: Documents

    Documents 11.1 Assembly report Frame number: Date: Components Description Criteria Measures if rejected Assembly/ Accept- Tests Rejection inspection ance Front wheel Assembly O.K. Loose Adjust quick release Kickstand Check mount fastening Functional check O.K. Loose Retighten screws Tyre pressure too low/ Tyres Tyre pressure check O.K.
  • Page 208 Drive/gear shift Chain/cassette/ Refasten if necessary or replace Check for damage O.K. Damage pinion/chainring as specified in parts list Chain guard/spoke Check for damage O.K. Damage Replace as specified in parts list guard Bottom bracket axle/ Check mount fastening O.K. Loose Retighten screws crank...

  • Page 209: Maintenance Log

    11.2 Maintenance log Diagnosis and documentation of current status Date: Frame number: Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Check mount Kickstand 6 months Functional check O.K.
  • Page 210 Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Brake system Check mount Brake lever 6 months O.K. Loose Retighten screws fastening Top up brake fluid; Depending on time of take Pedelec out of Brake fluid 6 months Check fluid level O.K.
  • Page 211 Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Electric drive Check for damage Functional check O.K. No screen, Restart, test battery, On-board defective new software or new 6 months computer screen display on-board computer; take out of service Drive Check for Functional check O.K.
  • Page 212 Notes MY22H03 - 32_1.0_04.10.2021...

  • Page 213: Nos Fs

    Documents 11.2.1 Nos FS 2.1 22-R-0001 Frame … Aluminium Fork ROCKSHOX, Lyrik Select Deflection: 150 mm; DebonAir + RC charger, lockout Damper ROCKSHOX, Deluxe Select+ RL Steering headset … Aheadset, integrated Handlebars Aluminium, 31.8 mm Handles MTB 1670D3 with clamping ring Stem …...
  • Page 214 Documents Lock ABUS, ABUS IT1 Plus Battery lock Stand/stand mount … … Motor SHIMANO EP8 DU-EP800 250 Watt, 85 Nm Rechargeable battery SIMPLO On-board computer SHIMANO EP8 with EP8 switch Charger SIMPLO ...not available # Not yet available when the instructions were produced MY22H03 - 32_1.0_04.10.2021...

  • Page 215: Glossary

    Glossary Glossary Bicycle for young adults Disc brake Source: ISO 4210-2: pedelec designed for use on Source: EN 15194:2017: brake in which brake public roads by a young adult whose weight is less pads are used to grip the lateral faces of a thin than 40 kg, with maximum saddle height of disc attached to or incorporated into the wheel 635 mm or more and less than 750 mm (see...
  • Page 216 Glossary Fork steerer Maximum tyre pressure Source: EN 15194:2017: part of a fork that rotates Source: EN 15194:2017: maximum tyre pressure around the steering axis of a pedelec frame head recommended by the tyre or rim manufacturer for tube. It is normally connected to the fork crown or a safe and efficient performance.
  • Page 217 Glossary Placing on the market Shut-off speed Source: Directive 2006/42/EC on Machinery, Source: EN 15194:2017: speed reached, by the 17.05.2006, Making available for the first time in pedelec, at the moment the current has dropped the Community machinery or partly completed to zero or to the no load current value.

  • Page 218: Abbreviations

    Glossary Wheel Source: ISO 4210 - 2: unit or combination of hub, rim and spokes or disc, but excluding tyre assem- bly. Work environment Source: ISO 9000:2015: set of conditions under which work is performed. Year of manufacture Source: ZEG: the year of manufacture is the year in which the pedelec was manufactured.

  • Page 219: Appendix

    The following other technical standards have been applied: • EN 11243:2016: Cycles – Pannier racks for bicycles – Requirements and test methods Cologne, 19/04/2021 ………………………………………………………………………………………………………………… Georg Honkomp, Managing Director, HERCULES GmbH * Community member who is authorised to compile the technical documentation MY22H03 - 32_1.0_04.10.2021...

  • Page 220: Declaration Of Conformity For Incomplete Machine

    Appendix Declaration of Conformity for incomplete machine 2006/42/EC DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY (Original) SHIMANO INC. 1. Business name and full address of the manufacturer and, where appropriate, his authorized representative; SHIMANO INC. 3-77 Oimatsu-cho, Sakai-ku, Sakai City, Osaka, Japan 2.
  • Page 221 Appendix MY22H03 - 32_1.0_04.10.2021...

  • Page 222: Red Declaration Of Conformity

    Appendix RED Declaration of Conformity MODEL: SC-EM800 RI-7H90D-000 Regional regulatory information Europe Česky [Czech] Tímto SHIMANO INC. prohlašuje, že typ rádiového zařízení SC-EM800 je v souladu se směrnicí 2014/53/EU. Úplné znění EU prohlášení o shodě je k dispozici na této internetové adrese: http://si.shimano.com Dansk [Danish] Hermed erklærer SHIMANO INC., at radioudstyrstypen SC-EM800 er i overensstemmelse med direktiv 2014/53/EU.
  • Page 223 Appendix Canada Korea This device complies with Industry Canada license-exempt RSS standards. Operation is MSIP-CRM-WY7-SWAN-2 R-R-WY7-3A subject to the following two conditions: 1. this device may not cause interference, and 2. this device must accept any interference, including interference that may cause undesired operation of the device.

  • Page 224: Keyword Index

    Keyword index Keyword index - preparing, 59 – servicing, 140, 145 Front derailleur, Air valve, 31 - cleaning, 143 Articulated shaft, Carbon seat post Front wheel brake, 39 - caring for 148 – servicing, 147 - braking, 128 Axle, 31 Cassette, Front wheel, see Wheel - cleaning, 143...
  • Page 225 Keyword index Seat post, 25, 40 - cleaning, 142 Minimum insertion depth – servicing, 147 marking, 76 Shifter, Motor cover 16 - cleaning, 143 Motor, – servicing, 148 - cleaning, 141 Spoke nipples, 37 Mudguard 16 – servicing, 147 - cleaning, 142 Spoke, 36 –...

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