Page 1 IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE Translation of original operating instructions for KETTLER pedelecs with BOSCH Intuvia on-board computer Scarpia FS1 LTD, Scarpia FS2 and Scarpia FS3 KS127-IxxD to KS129-IxxD MY22 K03 - 32 _1. 0_2 0:0 4:20 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 FOX 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 6.6.6.4 Adjusting the angle-adjustable stem 6.6.7 Ergonomic handles 6.6.7.1 Checking handlebar stability 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...
Page 6 Contents 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 Rechargeable battery 6.19.1 Removing the BT-E8036 battery...
Page 7 Contents 7.2.7 Cleaning the rear frame damper Basic cleaning 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...
Page 8 Contents 7.5.1.6 Checking the rim hooks 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...
Page 9 Contents Rechargeable battery Lighting 9.4.1 On-board computer error Miscellaneous 9.5.1 Other errors 9.5.2 FOX suspension fork 9.5.2.1 Rebound too fast 9.5.2.2 Rebounding too slowly 9.5.2.3 Suspension too soft on inclines 9.5.2.4 Excessively hard damping on bumps 9.5.3 FOX rear frame damper 9.5.3.1 Rebound too fast 9.5.3.2...
Page 10 About these operating instructions Thank you for your trust! Copyright KETTLER pedelecs are premium quality vehicles. © KETTLER Alu-Rad GmbH You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product.
Page 11: About These Operating Instructions
About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and KETTLER Alu-Rad GmbH actions. You will find three warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany WARNING Tel.: +49 6805 6008-0...
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 Chargers with excessive voltage damage 2.1.1.1 Rechargeable battery batteries. This may cause a fire or an explosion. The safety electronics may fail if the batteries are damaged or faulty. The residual voltage can ...
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
EN 15194 0,25 kW / 25 km/h zGG 180 kg EPAC 25 kg BJ 2021 / MJ 2022 Figure 1: Example KETTLER nameplate More No. Designation Description information The manufacturer uses the CE marking to declare that the pedelec CE marking complies with applicable requirements.
Page 26: Components
Description Components 3.3.1 Overview 15 16 17 Figure 2: Pedelec viewed from the right, example Front wheel Frame Chain guard Front wheel hub Seat post Motor (rear motor cover) Fork Saddle Pedal Steering headset Rear wheel brake Frame number Handlebars Rear wheel hub Battery and nameplate (in Stem...
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 MY22K03 - 32_1.0_13.09.2021...
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: Fox Rear Frame Damper
Overview 3.3.3.3 FOX 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 MY22K03 - 32_1.0_13.09.2021...
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 MY22K03 - 32_1.0_13.09.2021...
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 MY22K03 - 32_1.0_13.09.2021...
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)
Overview 3.4.6 Battery level indicator (battery) The pedelec has a BMZ V10: Figure 51: Overview of SHIMANO BT-E8036 battery On-Off button Battery level indicator LED MY22K03 - 32_1.0_13.09.2021...
Page 54: Technical Data
Overview Technical data 3.5.1 Pedelec 3.5.5 SHIMANO SC-EM800 on-board computer Operating temperature -5…+40 °C Transportation temperature -20…+60 °C Storage temperature -10…+40 °C Storage temperature -20…+70 °C Charging temperature 0…+40 °C Operation temperature -10…50 °C Protection class IPx7 Charging ambient temperature 0 °…40 °C (with USB cover closed) Power output/system...
Page 55: Emissions
Overview 3.5.6 Emissions The safety requirements as per Electromagnetic Compatibility Directive 2014/30/EU have been met. The pedelec and the charger can be used in residential areas without restriction. A-weighted emission sound <70 dB(A) pressure level Total vibration level for the hands <2.5 m/s²...
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 KS127-xxKD KS128-xxKD Table 25: 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: Installing Wheel In The Fox Fork
Assembly 5.3.3 Installing wheel in the FOX fork 5.3.3.1 Quick release (15 mm) Only applies to FOX forks with 15 mm screw-on axle The same procedure is used for installing both the Setting quick releases 15 x 100 mm and 15 x 110 mm quick releases. ...
Page 65: Kabolt Axle
Assembly 5.3.3.2 Kabolt axle Only applies to FOX forks with Kabolt axles 1 Place the front wheel in the fork ends of the fork. Push the Kabolt axle through the fork end on the non-drive side and hub. Figure 58: Pushing the Kabolt axle in 2 Tighten the Kabolt axle screw to 17 Nm (150 in-lb) with a 6 mm hex key.
Page 66: Preparing The Limotec Seat Post
Assembly 5.3.4 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 67: Fitting The Pedals
Assembly 5.3.5 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 68: Checking The Stem And Handlebars
Assembly 5.3.6 Checking the stem and handlebars 5.3.6.1 Checking the connections 5.3.6.3 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 69: 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 70 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 71: 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 72: 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 73: On-Board Computer Warnings
Operation On-board computer warnings 6.3.2 Figure 62: 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 74: 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 75: 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 76: 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 77: 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 78: 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 79: 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 80: 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 81: 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 82: 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 83: 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 84: 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 79: 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 85: 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 81: Correct (1) and incorrect (2) position of the handle 1 Undo the handle screw.
Page 86: 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 87: 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 88: 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 89: 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 90: 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 91: 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 92: Suspension
Operation 6.6.11 Suspension A pedelec’s fork suspension and rear frame  Follow 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 93 Operation Increasing air pressure with EVOL air chambers Only applies to pedelecs with this equipment Balance the air pressure between the positive and negative air chambers by slowly compressing the fork by 25% of the deflection after every increase of the air pressure by 3.5 bar (50 psi) 10 to 20 times.
Page 94: Adjusting Fox Fork
Operation 6.6.12.1 Adjusting FOX fork Only applies to pedelecs with this equipment  The air valve is located beneath the blue air 8 Get off the pedelec without allowing it to valve cap on the crown. Twist off the air valve deflect.
Page 95: Adjust The Rear Frame Damper Sag
Operation 6.6.13 Adjust the rear frame damper sag Adjustments 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 (30%) A greater sag increases sensitivity to bumps, thus producing greater suspension motion.
Page 96: Adjusting Fox Rear Frame Damper
Operation 6.6.13.1 Adjusting FOX rear frame damper Only applies to pedelecs with this equipment  The fork sag is adjusted. 4 Slowly compress damper 10 times by 25% of the deflection. The air pressure between the  When adjusting the sag, ensure that all dampers positive and negative air chambers is are in the open position, i.e.
Page 97 Operation 13 Compare measurement to the value from the Recommended FOX rear frame damper sag table. The sag may be adjusted, depending on the rider's preferences (20 to 30%). Deflection Hard, 25% sag Soft, 30% sag [mm (in)] [mm (in)] [mm (in)] 38 (1.5) 10 (0.38)
Page 98: 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 99: Adjusting Fox Suspension Fork
Operation 6.6.14.1 Adjusting FOX suspension fork Only applies to pedelecs with this equipment Figure 92: FOX rebound screw (1) under fork cap (2)  The fork sag is adjusted. 1 Remove fork cap. 1 Turn rebound screw in the clockwise direction to the closed position until it stops.
Page 100: 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 101: Adjusting Fox Rear Frame Damper
Operation 6.6.16.1 Adjusting FOX rear frame damper Only applies to pedelecs with this equipment  The sag in the rear frame damper is adjusted. Adjusting Float DHX rebound Only applies to pedelecs with this equipment Adjusting Float DPS and Float X rebound Only applies to pedelecs with this equipment Figure 95: Float DHX rebound adjuster (1) Figure 94: Float DPS (1) and Float X (2) rebound adjusters...
Page 102: 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 103: 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 99: Light positioned too high (1), correctly (2) and too low (3) 7 Check the position of the light beam.
Page 104: 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 105: 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 103: MTB control panel Switch...
Page 106: 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 107: 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 108: 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 109: Adjusts The Gear Shift
Operation 6.6.20.10Adjusts the gear shift 6.6.20.11 RD 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 110: 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 111: 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 112: 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 113: Trailer
Crash caused by brake failure KETTLER The braking distance may be longer if the trailer is carrying excessive load. The long braking KETTLER QUADRIGA child trailer. distance can cause a crash or an accident and injuries. BURLY  Never exceed the specified trailer load.
Page 114: 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 115: 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 116: 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 117: Raising The Kickstand
Operation 6.16 Using the pedals  The ball of the foot is placed on the pedal when riding and pedalling. Figure 117: The maximum load bearing (1) capacity is indicated on the pannier rack.  Never exceed the maximum permitted total weight when packing the pannier.
Page 118: Rechargeable Battery
Operation 6.19 Rechargeable battery  Switch off the battery and the drive system before removing or inserting the battery. 6.19.1 Removing the BT-E8036 battery 1 Open the key hole flap. 2 Insert key in the locking cylinder. Figure 121: Battery is unlocked 5 Press on the double latch plate.
Page 119: Inserting The Bt-E8036 Battery
Operation 6.19.2 Inserting the BT-E8036 battery 1 Place battery into the mount with the contacts facing the front. 2 Push battery into the frame. Figure 124: LED light on the charger (1) The LED on the charger has three statuses: Status Meaning Lights up...
Page 120: 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 121: 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 122: Using The Riding Light
Operation MTB control panel The on-board computer has one button (1) and a display screen (2). Figure 128: MTB control panel Figure 129: 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 123: 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 130: Changing from main display screen to DST hands when using push assist.
Page 124: 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 125: Suspension And Damping
Operation 6.23 Suspension and damping 6.23.0.1 Damper compression adjuster of the fork 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.
Page 126: Compression Adjuster On Rear Frame Damper
Operation 6.23.1 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 127: Adjusting Fox Compression Damper Of The Fork
Operation 6.23.1.1 Adjusting FOX compression damper of the fork The 3-way lever enables you to make quick Only applies to pedelecs with this equipment adjustments to the suspension behaviour in the The adjuster for open mode offers 18 additional fork to suit changes in terrain. It is intended for fine adjustments for OPEN mode.
Page 128: Adjusting Fox Compression Damper Of The Rear Frame Damper
Operation 6.23.1.2 Adjusting FOX compression damper of the rear frame damper The 3-way lever enables you to make quick The adjuster for open mode offers three adjustments to the suspension behaviour in the additional fine adjustments for OPEN mode. The damper to suit changes in terrain.
Page 129: 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 130: 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 131 Operation 2 Pull handlebars into highest possible position. Figure 140: All Up pulled into highest possible position 3 Turn handlebars 90° in a clockwise direction. Figure 141: All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever. MY22K03 - 32_1.0_13.09.2021...
Page 132: 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 133 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 134 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 135 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 136: 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 137: 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 138: 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 139: 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 140: 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 141: 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 142: 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 143: Servicing
Cleaning and servicing Servicing Complying with these servicing instructions is the 7.4.1 Frame only way to reduce wear on components, increase the operating hours and guarantee safety. Notice  Hard wax polish and protection wax are particularly resistant on gloss paintwork. These car accessory retail products are unsuitable for matt paint finishes.
Page 144: Pannier Rack
Cleaning and servicing 7.4.3 Pannier rack 7.4.6 Stem 1 Dry pannier rack with a cloth. 1 Spray painted and polished metal surfaces with wax spray and leave to dry. 2 Spray pannier rack with spray wax and leave to dry. 2 Wipe away any wax residue with a cloth.
Page 145: Leather Handle
Cleaning and servicing 7.4.10 Leather saddle 7.4.8.2 Leather handle Standard leather care products keep leather Standard leather care products keep leather smooth and resistant, brighten its appearance and smooth and resistant, brighten its appearance and improve or replace stain protection. improve or replace stain protection.
Page 146: Gear Shift
Cleaning and servicing 7.4.14 Gear shift links. The faster the crank is turned, the thinner the threads of oil will be. 7.4.14.1 Rear derailleur articulated shafts and jockey wheels  Treat front and rear derailleur articulated shafts and jockey wheels with Teflon spray. 7.4.14.2 Shifter Notice Figure 143: Lubricating the chain...
Page 147: Caring For The Brake
Cleaning and servicing 7.4.17 Caring for the brake 7.4.17.1 Caring for the brake Notice  Never treat brake levers with degreaser or penetrating oil spray.  Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision mechanics oil.
Page 148: 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 149 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 150: 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 151: 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 152: 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 153: 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 154: 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 155: 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 156: 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 157: 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 158: 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 159: 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 160 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 161 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 162: 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 163: 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 164 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 165 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months … Section 7.4.13 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 166 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 167 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 168 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 169 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 170: 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 171: 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 172: 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 173: 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 174: 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 175: 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 176: 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 177 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 168: Removed spring washer Figure 166: Pulling the end cap out 2 Carefully remove the wiper from the groove.
Page 178 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 179 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 180 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 181 Maintenance 9 Carefully insert slide bushing tube into the seat tube. Figure 193: Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper. Figure 190: Inserting the slide bushing tube into the seat tube 10 Place outer sleeve on the seat tube and push downwards firmly.
Page 182: 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 183 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 204: Removing the wiper Figure 208: inserting and fastening the wiper 5 Use a small, sharp object to look for and remove the end of the felt ring.
Page 184 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 209: Cleaning the slide bushing tube Figure 212: Cleaning the longitudinal groove Notice 4 Apply grease into the longitudinal groove and on both cross-pieces.
Page 185 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 186: 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 187: 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 188: 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 189: 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 190: 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 191: 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 192: 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 193: Other Errors
Troubleshooting, fault clearance and repair 9.5.1 Other errors Symptom Cause Remedy Two beeps will sound if a Pressed switch mode has been  This is not a malfunction. switch is pressed but the deactivated. switch cannot be operated.  This occurs when a warning or an error is shown on the on- Three beeps are A fault or warning has sounded.
Page 194: Fox Suspension Fork
Troubleshooting, fault clearance and repair 9.5.2 FOX suspension fork 9.5.2.1 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 195: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.5.2.2 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 196: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.5.2.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. weight shifts forward and the pedelec loses some The deflection is quickly used up, the rider's momentum. Figure 225: Excessively soft suspension in the suspension fork on hilly terrain Solution Only applies to pedelecs with this equipment Figure 226: 3-way lever with modes...
Page 197: 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 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 198: Fox Rear Frame Damper
Troubleshooting, fault clearance and repair 9.5.3 FOX rear frame damper 9.5.3.1 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 199: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.5.3.2 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 200: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.5.3.3 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 235: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 236: 3-way lever with modes ...
Page 201: Excessively Hard Damping On Bumps
Troubleshooting, fault clearance and repair 9.5.3.4 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 202: 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 203: 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 204 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 205: Parts List
Documents 10.2 Parts list 10.2.1 SCARPIA FS 1 LTD KS127-xxKD Frame Aluminium Fork FOX, 36 Performance Elite Deflection: 150 mm Damper FOX FLOAT DPS PERFORMANCE ELITE … SERIES Steering headset ACROS, AZF-584 1.5 inch Handlebars CRANK BROTHERS Handlebar width: 750 mm Handles ERGON, GD10 …...
Page 206 Documents Motor SHIMANO, Steps DU-EP800A 25 85 Nm Rechargeable battery BMZ Supercore 750 36V UART/FIT 750 Wh Display SHIMANO, Steps SC-EM800 … Charger FIT 36 V charger 4.5 Ah ...not available # Not yet available when the instructions were produced MY22K03 - 32_1.0_13.09.2021...
Page 207: Scarpia Fs
Documents 10.2.2 SCARPIA FS 2 KS128-xxKD Frame … Aluminium Fork FOX, 36 Performance Elite Deflection: 150 mm Damper FOX FLOAT DPS Performance … Headset Acros AZF-584 1.5 inch Handlebars CRANK BROTHERS Handlebar width: 750 mm Handles ERGON, GD10 … Stem CRANK BROTHERS 35 mm Saddle...
Page 208 Documents Display SHIMANO, Steps SC-EM800 … Charger FIT 36 V charger 4.5 Ah ...not available # Not yet available when the instructions were produced MY22K03 - 32_1.0_13.09.2021...
Page 209: 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 210 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 211 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 212: 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 213: Appendix
Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* Janine Otto ZEG Zweirad-Einkaufs-Genossenschaft eG c/o ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Str. 2 Longericher Strasse 2 50739 Köln, Germany 50739 Köln, Germany The machine, pedelec types: KS127-xxKD Scarpia FS 1 LTD Mountain bike...
Page 214: 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 215 Appendix MY22K03 - 32_1.0_13.09.2021...
Page 216: 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 217 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 218: Keyword Index
Keyword index Keyword index - cleaning, 139 – servicing, 137 Air valve, 31 Carbon seat post Front derailleur, 41 Articulated shaft, – caring for, 144 - cleaning, 140 - caring for 145 Cassette, Front wheel brake, 39 Axle, 31 - cleaning, 140 - braking, 123 Chain guard 16 Front wheel, see Wheel...
Page 219 Keyword index Seat post, 25, 40 – caring for, 144 Minimum insertion depth - cleaning, 139 marking, 78 Shifter, Motor cover 16 – caring for, 145 Motor, - cleaning, 140 - cleaning, 138 Spoke nipples, 37 Mudguard 16 – caring for, 144 –...

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Shimano ks128 series

Kettler SHIMANO KS127 Series Translation Of Original Operating Instructions

Table of Contents

1 About These Operating Instructions

2 Safety

3 Description

4 Transporting and Storing

5 Assembly 5.1 Unpacking

6 Operation

Pedelec Adjustment Procedure

7 Cleaning, Servicing and Maintenance

8 Maintenance

9 Troubleshooting, Fault Clearance and Repair

10 Recycling and Disposal

12 Glossary

13 Appendix

14 Keyword Index

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