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Kettler Quadriga Comp Belt Translation Of Original Operating Instructions

Pedelecs with bosch kiox on-board computer

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IMPORTANT

READ CAREFULLY BEFORE USE

KEEP SAFE TO CONSULT AT A LATER DATE

Translation of original operating instructions for

KETTLER Pedelecs with BOSCH Kiox

on-board computer

Quadriga

Comp Belt, Comp CX 11, Cross Pro CX 11, Duo CX10, Duo CX12, Duo CX12 FS, Duo CX12 FS SUV, Duo CX5,

Q u a d r i g D U O C X E - T R, Q u a d r i g D U O C X 1 2 , Q u a d r i g D U O C X 1 2 F S , Q u a d r i g D U O C X 1 2 SU V F S , Q u a d -

Duo E-TR Belt, Pro Belt, PRO Belt, Pro CX 11, SUV Urban, Town & Country C1, Town & Country C2

r ig P r o B e l t , Q u a d r i g P r o CX 1 2 , Q u a d r i g To w n & C o u n t r y Pr o

Scarpia

FS 1.0 LTD Gold, FS 1.0 LTD Silver, FS 2.0, FS 3.0

KB060-xxKD, KB061-xxFD, KB063-xxKD, KB064-xxFD, KB089-xxKD...xxKW, KB091-xxKD, KB103-xxKD,

K B 11 0 - Z X K D , K B 11 0 - Z X K T, K B 11 0 - Z X K W, K B 11 5 - Z X KD , K B 11 5 - Z X K T, K B 11 5 - Z X K W, KB 1 2 8 - Z X K D ,

KB128-xxKD...xxKW, KB129-xxFD...xxFW, KB131-xxKD, KB132-xxFD...xxFW, KB138-xxKD...xxKD,

K B 1 2 8 - Z X K W, K B 1 2 9 - Z X K D , K B 1 2 9 - Z X K W, K B 1 3 1 - Z X K D , K B 1 3 2 - Z X F D , KB 1 3 2 - Z X F W, K B 1 3 8 - Z X K D

KB145-xxKD...xxKW, KB146-xxFD...xxFW, KS127-xxKD, KS128-xxKD, KS129-xxKD, KS130-xxKD

TRANSLATION OF THE ORIGINAL

OPERATING INSTRUCTIONS

IMPORTANT

READ CAREFULLY BEFORE USE

MY2 2K01 - 3 2_1 .0_ 20:0 4:2021

MY22 K01 - 32 _1.0 _ 26.08.20 21

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Summary of Contents for Kettler Quadriga Comp Belt

Page 1 IMPORTANT READ CAREFULLY BEFORE USE Translation of original operating instructions for KETTLER Pedelecs with BOSCH Kiox on-board computer Quadriga Comp Belt, Comp CX 11, Cross Pro CX 11, Duo CX10, Duo CX12, Duo CX12 FS, Duo CX12 FS SUV, Duo CX5, Q u a d r i g D U O C X E - T R, Q u a d r i g D U O C X 1 2 , Q u a d r i g D U O C X 1 2 F S , Q u a d r i g D U O C X 1 2 SU V F S , Q u a d - Duo E-TR Belt, Pro Belt, PRO Belt, Pro CX 11, SUV Urban, Town &...
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 Wheel 3.3.3.1 Tyres 3.3.3.2 3.3.3.3 Valve 3.3.3.4 Spoke 3.3.3.5 Spoke nipples 3.3.3.6 3.3.4 Braking system 3.3.4.1 Mechanical brake 3.3.4.2 Hydraulic brake 3.3.4.3 Disc brake 3.3.4.4 Rim brake...
Page 4 Contents 3.4.2.10 Activity tracking 3.4.2.11 Lock function (premium function) 3.4.2.12 System message 3.4.3 Control panel 3.4.4 Gear shift 3.4.4.1 SHIMANO SW-E7000 derailleur gears 3.4.4.2 ENVIOLO hub gear 3.4.5 Hand brake 3.4.6 Battery level indicator (battery) 3.4.6.1 Battery level indicator (battery) Technical data 3.5.1 Pedelec...
Page 5 Contents 5.3.5 Preparing the LIMOTEC seat post 5.3.6 Fitting the pedals 5.3.7 Checking the stem and handlebars 5.3.7.1 Checking the connections 5.3.7.2 Checking stem is firmly in position 5.3.7.3 Checking the headset backlash Pedelec sale Operation Risks and hazards Tips for a greater range Error message 6.3.1 On-board computer...
Page 6: S E Tti N G
Contents 6.5.14.2 Adjusting the RockShox suspension fork 6.5.15 Adjusting the rear frame damper rebound damper 6.5.15.1 Adjusting the RockShox rear frame damper 6.5.16 Compression adjuster on rear frame damper 6.5.16.1 Adjusting the RockShox compression adjuster 6.5.17 Adjust on-board computer 6.5.17.1 Creating a user account 6.5.17.2 Connecting the on-board with the smartphone...
Page 7 Contents 6.16.2 Pannier rack battery 6.16.2.1 Removing the pannier rack battery 6.16.2.2 Inserting the pannier rack battery 6.16.3 Integrated battery 6.16.3.1 Removing the integrated battery 6.16.3.2 Inserting the integrated battery 6.16.4 Charging the battery 6.16.5 Charging the dual battery 6.16.5.1 Charging process when two batteries are used 6.16.5.2 Charging process when one battery is used...
Page 8 Contents 7.1.14 Checking the brake After each ride 7.2.1 Cleaning the lights and reflectors 7.2.2 Cleaning the suspension fork 7.2.3 Caring for the suspension fork 7.2.4 Cleaning the pedals 7.2.5 Cleaning the brake 7.2.6 Cleaning the suspension seat post 7.2.7 Cleaning the rear frame damper Basic cleaning 7.3.1...
Page 9 Contents 7.4.18 Lubricating the eightpins seat post tube Maintenance 7.5.1 Wheel 7.5.1.1 Checking the tyre pressure 7.5.1.2 Checking the tyres 7.5.1.3 Checking the rims 7.5.1.4 Checking the nipple holes 7.5.1.5 Checking the nipple well 7.5.1.6 Checking the rim hooks 7.5.1.7 Checking the spokes 7.5.2 Checking the brake system...
Page 10 Contents 8.5.8.5 Eightpins H01 seat post 8.5.9 Rear frame damper 8.5.9.1 FOX component-specific maintenance Troubleshooting, fault clearance and repair Troubleshooting and fault clearance 9.1.1 Drive system or on-board computer does not start up 9.1.2 Error message 9.1.3 Errors in the assistance function 9.1.4 Battery errors 9.1.5...
Page 11 Contents Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Declaration of conformity for incomplete machine III. Directive declaration of conformity with RED Directive Keyword index MY22K01 - 32_1.0_26.08.2021...
Page 12 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 13: 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 14: Type Number And Model
KB063-xxKD Quadriga Comp CX 11 City and trekking bicycle The operating instructions identification number is KB064-xxFD Quadriga Comp Belt Mountain bike located in bottom left-hand corner of each page. KB089-xxKD Quadriga Town & Mountain bike Country C1 The identification number is composed of the...
Page 15: 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 16: 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 17: 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 18: 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 19: 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 20: 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 21: 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 22: 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 23: 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 24: Permitted Total Weight (Ptw)
Type no. Model PTW [kg] KB060-xxKD Quadriga Pro CX 11 KB061-xxFD Quadriga Pro Belt KB063-xxKD Quadriga Comp CX 11 KB064-xxFD Quadriga Comp Belt KB089-xxKD Quadriga Town & Country C1 KB089-xxKW Quadriga Town & Country C2 KB091-xxKD Quadriga SUV Urban KB103-xxKD...
Page 25: Environmental Requirements
Description 3.1.3 Environmental requirements You can be ride the pedelec within a temperature Temperatures under -5 °C and over +40 °C must range between -5 °C and +40 °C. The electric be avoided. drive system is limited in its performance outside You must also keep within the following this temperature range.
Page 26 Description The pedelec is unsuitable for the following areas of use: Child's bicycles/ City and trekking Area of use bicycles for Mountain bikes Racing bicycle Cargo bike Folding bicycle bicycles young adults Never drive off-road Never drive off-road Never drive off-road Never drive off-road Never drive off-road or perform jumps.
Page 27: 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 28: Components
Description Components 3.3.1 Overview 21 22 23 Figure 2: Pedelec viewed from the right Front wheel Seat post Chain Front wheel hub Saddle Chain guard Fork Pannier rack Frame number Front wheel mudguard Rear light Motor and motor cover Steering headset Rear wheel mudguard Pedal Front light...
Page 29: 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 30: 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 31: Wheel
Description 3.3.3 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 32: 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 33: Braking System
Description 3.3.4 Braking system A pedelec's brake system is primarily operated 3.3.4.2 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 34: Disc Brake
Description 3.3.4.3 Disc brake Figure 14: 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 35: Rim Brake
Description 3.3.4.4 Rim brake Figure 15: Brake system with rim brake in detail – MAGURA HS22 used as an example Rear wheel rim brake The rim brake stops the wheel moving when the Brake lining rider pulls the brake lever, causing two brake Brake booster linings, positioned opposite one another, to press Handlebars with brake lever...
Page 36: Back-Pedal Brake
Description 3.3.4.5 Back-pedal brake Figure 17: Brake system with a back-pedal brake – example Rear wheel rim brake Handlebars with brake lever Front wheel rim brake Pedal Back-pedal brake The back-pedal brake stops the rear wheel from moving by pushing the pedals in the opposite direction to the direction of travel.
Page 37: Seat Post
Description 3.3.5 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 38: Mechanical Drive System
Description 3.3.6 Mechanical drive system The pedelec is driven by muscle power, just like a 3.3.6.1 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 39: Electric Drive System
Description 3.3.7 Electric drive system The pedelec has an electric drive system in 3.3.7.2 Rechargeable battery addition to a mechanical one. BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards. Each individual cell is protected by a steel cup and encased in a plastic battery housing.
Page 40: Charger
Description Frame battery 3.3.7.3 Charger Each pedelec is supplied with a charger. As a general rule, any BOSCH charger may be used: • The 2 A compact charger • The 4 A standard charger • The 6 A fast charger Observe the operating instructions in the Section 11.4 Documents.
Page 41: Suspension
Description 3.3.9 Suspension Both forks and suspension forks are fitted in this model series. 3.3.9.1 Rigid fork Rigid forks do not feature suspension. They transfer the used muscle and motor power to the road to optimum effect. Pedelecs with rigid forks consume less energy on steep roads and have a greater range than pedelecs with suspension.
Page 42 Description Negative deflection (sag) The negative deflection (sag) is the percentage of optimally adjusted. The wheel stays in contact total deflection that is compressed by body with the ground when passing over bumps (blue weight, including equipment (such as a line).
Page 43 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 44 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 45: Rear Frame Damper
Overview 3.3.9.3 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 46 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 36: Optimum rear frame damper ride performance over bumps MY22K01 - 32_1.0_26.08.2021...
Page 47 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 48: Rockshox Rear Frame Damper
Description 3.3.9.4 RockShox rear frame damper The rear frame damper features air suspension, a compression damper and a rebound damper. Figure 39: Monarch RL as an example Threshold lever Rebound damper adjuster Air valve O-ring Scale MY22K01 - 32_1.0_26.08.2021...
Page 49: Electric Drive System
Description 3.3.10 Electric drive system The pedelec has an electric drive system in The pedelec does not have a separate emergency addition to a mechanical one. shut-off button. In the event of an emergency, the motor can be stopped by removing the on-board computer.
Page 50: Frame Battery
Description Battery performance is reduced when the 3.3.10.4 Pannier rack battery temperature drops since this increases electrical Three different types of pannier rack batteries can resistance. As a result, you can expect the range be fitted: to be shorter than normal in winter. We recommend using thermal protection sleeves when riding longer distances in the cold.
Page 51: Integrated Battery
Description 3.3.11 Lighting 3.3.10.5 Integrated battery Four different types of pannier rack batteries can When the riding light is activated, the front light be fitted: and the rear light are switched on together. PowerTube PowerTube PowerTube PowerTube (vertical and horizontal) Figure 45: Overview of integrated battery Figure 46: Integrated battery in detail Battery key...
Page 52: On-Board Computer
Overview 3.3.12 On-board computer The pedelec has a BOSCH Kiox on-board will only be logged if the on-board computer is computer. connected to the eBike Connect app. The on-board computer controls the drive system 3.3.12.1 USB port and shows the journey data on the display screen. There is a USB port under the rubber cover The drive system can be switched off by removing beneath the on-board computer.
Page 53: Description Of Controls And Screens
Description Description of controls and screens 3.4.1 Handlebars Figure 49: Detailed view of handlebars with BOSCH Kiox on-board computer, example Rear wheel hand brake Control panel On-board computer Shifter Front wheel hand brake Bell Handle MY22K01 - 32_1.0_26.08.2021...
Page 54: On-Board Computer
Overview 3.4.2 On-board computer The on-board computer is operated using two 3 . 4 . 2 . 1 S T AR T S C R E E N buttons on its casing and the buttons on the The S T A R T S C R EE N will appear as soon as the control panel on-board computer is inserted into its mount.
Page 55 Overview Colour Level of assistance Explanation screen O FF When the drive system is switched on, the motor assistance is switched off. White The battery charge level is over 30%. The pedelec can be used like a normal bicycle by simply pedalling. The push Yellow The battery charge level is between 15% and 30%.
Page 56: Status Bar
Overview 9. Guidance bar 3 . 4 . 2 . 4 Q U IC K M E N U You can use the Q U I C K M E N U to display selected settings which can also be adjusted while you are riding.
Page 57 Overview → <Components> Menu Submenu Display for the components concerned → <FAQs> showing the serial number, hardware version, → <Intro to Kiox> software version and other specifications → <Certificates> relevant for components. → <License info> • Bluetooth® → <Contact us> →...
Page 58: Additional Journey Information For Eshift Shimano Di2 And Rohloff
Overview • Information Applies only to pedelecs with eShift with Shimano Information on the Kiox on-board computer. DI2 derailleur gears. The following additional function is available on the function display. → <Introduction to Kiox> Display Change Explanation of the key functions and screens. ADJ U ST G EA R This is where you can make a fine adjustment to the Shimano DI2.
Page 59: Activity Tracking
Overview 3.4.2.10 Activity tracking User recognition is required on a PC or smartphone to record activities. The rider needs to agree to location data being saved on the portal or the app to record activities. Only then will all activities be displayed on the portal or app.
Page 60: Control Panel
Overview 3.4.3 Control panel The on-board computer is controlled using six buttons on the control panel. Figure 53: Overview of the BOSCH control panel Symbol Designation < Back button Select button > Forward button Plus key Push assist button – Minus key Table 21: Overview of control panel MY22K01 - 32_1.0_26.08.2021...
Page 61: Gear Shift
Description 3.4.4 Gear shift 3.4.4.1 SHIMANO SW-E7000 derailleur gears Only applies to vehicles with this equipment The gear shift unit is on the left of the handlebars. The gear shift unit features 2 buttons. Figure 54: SHIMANO SW-E7000 gear shift Up button (gear shift) Down button (gear shift) MY22K01 - 32_1.0_26.08.2021...
Page 62: Enviolo Hub Gear
Description 3.4.4.2 ENVIOLO hub gear Only applies to vehicles with this equipment The Automatic+ system is integrated into the drive system and offers an automatic switching option. The automatic ENVIOLO gear shift includes a twist grip with an indicator. Figure 55: ENVIOLO twist grip with indicator Manual gear shift indicator Automatic gear shift indicator Twist grip...
Page 63: Hand Brake
Description 3.4.5 Hand brake There is a hand brake on the left and right of the handlebars. Figure 56: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example • The left-hand brake controls the front wheel brake.
Page 64: Battery Level Indicator (Battery)
Description 3.4.6 Battery level indicator (battery) Each battery has its own level indicator: 3.4.6.1 Battery level indicator (battery) The five green LEDs on the battery level indicator show the charge level when the battery is switched on. Each LED represents 20% of battery capacity. LED 1,2,3,4,5 Battery level 100…80%...
Page 65: Technical Data
Description Technical data 3.5.1 Pedelec 3.5.4 BOSCH Kiox on-board computer Power output/system 250 W (0.25 kW) Internal lithium ion battery 3.7 V, 230 mAh Shut-off speed 25 km/h Operating temperature -5 °C… +40 °C Storage temperature -10 °C…+50 °C Table 22: Pedelec technical data Charging temperature 0 °C…...
Page 66: Bosch Active Line Plus
Description 3.5.7 Rechargeable battery 3.5.6.2 BOSCH Active Line Plus Maximum continuous power rating 250 W 3.5.7.1 BOSCH PowerPack 300 Max. torque 50 Nm Nominal voltage 36 V DC Nominal voltage 36 V Protection class IP54 Nominal capacity 8.2 Ah Weight about 3.2 kg Energy 300 Wh...
Page 67: Bosch Powertube
Description 3.5.8 BOSCH Pedelec ABS BAS100 3.5.7.4 BOSCH PowerTube 400 Nominal voltage 36 V Operating temperature -5… +40 °C Nominal capacity 11 Ah Storage temperature 10… +60 °C Energy 400 Wh Protection class IPx7 Weight 2.9 kg Weight about 1 kg Protection class IP54 Table 37: BOSCH pedelec ABS BAS100 technical data...
Page 68: Tightening Torques
Description 3.5.9 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 69 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 70: Transporting And Storing
Transporting and storing Transporting and storing Weight and dimensions for transportation Weight and dimensions during transport KB146-xxFD KB146-xxFW KB128-xxKD Table 39: Type number, model and pedelec type * Vehicle weight without battery # Not yet available when the instructions were produced KB128-xxKW Designated handles, lifting points The box does not have any handles.
Page 71: 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 72: 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 73: 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 74: 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 75: Preparing The Battery
Assembly 5.3.2 Preparing the battery 5.3.2.1 Retrofitting the PowerTube adapter Only applies to pedelecs with this equipment A PowerTube Adapter 400 or 500 needs to be 3 Use a ratchet to remove the two 4 mm hexagon retrofitted to use a BOSCH PowerTube 625 screws in the PowerTube adapter.
Page 76 Assembly 6 Use a TORX® T25 wrench to fasten the screws into the battery mount. Figure 67: Fastening the battery mount MY22K01 - 32_1.0_26.08.2021...
Page 77: Fit Battery Cover Onto Bosch Powertube 625 Battery (Horizontal)
Assembly 5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach the upper interface (lock side) from the 3 Press to push the battery cover onto the BOSCH PowerTube 625 battery with a TORX® battery.
Page 78: Fit Battery Cover Onto Bosch Powertube 500 Battery (Horizontal)
Assembly 5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach the upper interface (lock side) from the 3 Screw the battery mounting plate onto the BOSCH PowerTube 625 battery with a TORX® PowerTube extension with original BOSCH T20 wrench.
Page 79: Installing The Wheel In The Suntour Fork
Assembly 5.3.3 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.3.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this equipment 4 Insert the securing screw on the non-drive side. ...
Page 80: Mm Cross Axle
Assembly 5.3.3.2 20 mm cross axle Only applies to Suntour forks with this equipment 2 Tighten the cross axle with the red handle. CAUTION Crash caused by loose quick release axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
Page 81 Assembly 5 Check the position and clamping force of the quick release lever. The quick release lever must be flush with the shock absorber. Figure 83: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 82: Q-Loc Quick Release
Assembly 5.3.3.3 Q-LOC quick release Only applies to Suntour forks with this equipment 1 Push in the quick release until you can hear a click. Make sure that the flange is extended. CAUTION Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel.
Page 83: Preparing The Wheel
Assembly 5.3.4 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 84: Preparing The Limotec Seat Post
Assembly 5.3.5 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 85: Fitting The Pedals
Assembly 5.3.6 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 86: Checking The Stem And Handlebars
Assembly 5.3.7 Checking the stem and handlebars 5.3.7.1 Checking the connections 5.3.7.3 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 87: 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 88 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 89: 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 90: Error Message
Operation Error message 6.3.1 On-board computer The drive system monitors itself continuously and Code Description Method of resolution displays a number as an error message if a known Battery internal error Re-start the system. error is detected. The system may switch off Contact your specialist automatically depending on the type of error.
Page 91 Operation Code Description Method of resolution Code Description Method of resolution Battery error Switch off system. 595, Communication error Check cabling to the gears. Remove the battery. Re-start the system. Re-insert battery. Contact your specialist Restart electric drive dealer if the problem system.
Page 92 Operation Code Description Method of resolution Code Description Method of resolution Internal fault Re-start the system. 860, Error in the power Re-start the system. supply Contact your specialist Contact your specialist dealer if the problem dealer if the problem persists. persists.
Page 93: Rechargeable Battery
Operation 6.3.2 Rechargeable battery The battery is protected against deep discharge, overcharging, overheating and short circuits by Electronic Cell Protection (ECP). In the event of a hazard, a protective circuit switches the battery off automatically. If a fault is detected in the battery, the LEDs flash on the battery level indicator.
Page 94: Instruction And Customer Service
Operation Instruction and customer service The supplying specialist dealer will provide 6.5.1 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 95: Pedelec Adjustment Procedure
Operation 6.5.2 Pedelec adjustment procedure  Observe the correct order for adjustment. For pedelecs with components only Sequence Adjustment Section order Saddle • Straighten saddle 6.5.4.1 • Adjust saddle height 6.5.4.2 • Adjust saddle position 6.5.4.4 • Adjust saddle tilt 6.5.4.5 Handlebars 6.5.5...
Page 96: Determining The Sitting Position
Operation 6.5.3 Determining the sitting position The starting point for a comfortable posture is the correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g. in the shoulder or back. Figure 94: The pelvis is in the right position (green) or incorrect position (red) The pelvis is in the right position if the spine forms...
Page 97 Operation Position on roadster Position on city bike Position on trekking Position on sports bike bike Upright, almost vertical Slightly inclined upper Considerably inclined Sharply inclined upper posture, body, upper body, body, back at an angle of back at an angle of 60°– back at an angle of 30°–...
Page 98: Adjusting The Saddle
Operation 6.5.4 Adjusting the saddle 6.5.4.1 Straightening the saddle 6.5.4.2 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 99: Setting The Saddle Height With The Remote Control
Operation 5 Open the quick release on the seat post to 6.5.4.3 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 100: Adjusting The Saddle Position
Operation 6.5.4.4 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 101: Handlebars
Operation 6.5.5 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 102: Stem
Operation 6.5.6 Stem 6.5.6.1 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 103: Setting The Quill Stem
Operation 6.5.6.2 Setting the quill stem 6.5.6.3 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 104: Adjusting The Angle-Adjustable Stem
Operation 6.5.6.4 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 109: 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 105: Ergonomic Handles
Operation 6.5.7 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 111: Correct (1) and incorrect (2) position of the handle 1 Undo the handle screw.
Page 106: Tyres
Operation 6.5.8 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 107: Brake
Operation 6.5.9 Brake The brake lever grip distance can be adjusted to 6.5.9.2 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 108: 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 109: Pressure Point On A Magura Brake Lever
Operation 6.5.9.4 Pressure point on a MAGURA brake lever Only applies to pedelecs with this equipment  Turn the twist knob towards the plus (+) WARNING symbol.  The brake lever moves closer to the handlebar Brake failure due to incorrect setting grip.
Page 110: Grip Distance On A Magura Disc Brake Lever
Operation 6.5.9.5 Grip distance on a MAGURA disc brake lever Only applies to pedelecs with this equipment affect the pressure point or the position of the WARNING brake linings.  Turn the setting screw/twist knob (5) anti- Crash caused by incorrectly set grip distance clockwise towards minus (–).
Page 111: Retracting The Brake Linings
Operation 6.5.9.6 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 112: Lighting
Operation 6.5.10 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 113 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 122: Light positioned too high (1), correctly (2) and too low (3) 7 Check the position of the light beam.
Page 114: Suspension
Operation 6.5.11 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 115: Adjusting The Suntour Fork Steel Suspension
Operation 6.5.12.1 Adjusting the Suntour fork steel suspension Only applies to pedelecs with this equipment 1 You will find the sag setting wheel (1) beneath the plastic cover on the crown. Remove the plastic cover. Figure 123: Sag setting wheel (1) on the suspension fork crown ...
Page 116: Adjusting The Suntour Fork Air Suspension
Operation 6.5.12.2 Adjusting the Suntour fork air suspension Only applies to pedelecs with this equipment  The air valve is located beneath the air valve 1 Attach a high-pressure damper pump to the air cap on the crown. Twist off the air valve cap. valve.
Page 117: Adjusting The Rockshox Fork Coil Spring With Spacer For Pre-Tensioning
Operation 6.5.12.3 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 118 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 128: 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 119: Adjusting The Rockshox Coil Spring With An External Preload Adjuster
Operation 6.5.12.4 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 120: Rockshox Paragon Silver Coil Spring
Operation 6.5.12.5 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 121 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 136: Screwing and unscrewing the preload adjustment ring ...
Page 122: Adjusting The Rockshox Fork Air Suspension
Operation 6.5.12.6 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 123 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 124: Adjust The Rear Frame Damper Sag
Operation 6.5.13 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 125: Adjusting The Rockshox Rear Frame Damper
Operation 6.5.13.1 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 126 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 127: Fork Rebound Damping
Operation 6.5.14 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 128: Adjusting The Suntour Fork Rebound Damping
Operation 6.5.14.1 Adjusting the Suntour fork rebound damping Only applies to pedelecs with this equipment Figure 145: Example of Suntour rebound screw (1)  The fork sag is adjusted. 1 Turn the rebound screw in a clockwise direction to the closed position until it stops. 2 Turn the rebound screw slightly in an anti- clockwise direction.
Page 129: Adjusting The Rockshox Suspension Fork
Operation 6.5.14.2 Adjusting the RockShox suspension fork Only applies to pedelecs with this equipment Figure 146: 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 130: Adjusting The Rear Frame Damper Rebound Damper
Operation 6.5.15 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 131: Adjusting The Rockshox Rear Frame Damper
Operation 6.5.15.1 Adjusting the RockShox rear frame damper Only applies to pedelecs with this equipment Figure 148: 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 132: Compression Adjuster On Rear Frame Damper
Operation 6.5.16 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 133: Adjusting The Rockshox Compression Adjuster
Operation 6.5.16.1 Adjusting the RockShox compression adjuster Only applies to pedelecs with this equipment Figure 150: 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 134: Adjust On-Board Computer
Operation 6.5.17 Adjust on-board computer 6.5.17.1 Creating a user account 6.5.17.4 Activating activity tracking  The rider needs to register online and create a Your location will only be logged if the on-board computer is connected to the eBike Connect app. user account to use all the drive system’s functions.
Page 135: Inserting The On-Board Computer
Operation 6.5.17.6 Inserting the on-board computer 2 Fold on-board computer gently forward until Notice you can feel it is attached to the magnetic mount.  Never use the on-board computer as a handle. The on-board computer may become irreparably damaged if you use it to lift the pedelec.
Page 136: Securing The On-Board Computer
Operation 6.5.17.7 Securing the on-board computer 6.5.17.8 Removing the on-board computer It is possible to secure the on-board computer so  The on-board computer can be removed if it is not secured. that it cannot be removed. Figure 155: Removing the on-board computer Figure 154: Position of headset screw 1 Grip the on-board computer by its top edge.
Page 137: Operating The On-Board Computer
Operation 6.5.17.9 Operating the on-board computer 6.5.17.10Opening the start screen  Insert on-board computer into the mount.  The S T A R T S C R E E N will be shown. Figure 156: Overview of control panel Symbol Designation Select button Figure 157:...
Page 138: Adjust On-Board Computer
Operation 6.5.17.14Adjust on-board computer   Select the desired setting using the Plus and The pedelec is stationary. You cannot open and adjust the settings while riding. Minus buttons.  The on-board computer is inserted and displaying  Press the Select button to confirm. the start screen.
Page 139: Setting The Clock Format
Operation 6.5.17.18Setting the clock format 6.5.17.23Configuring eShift 1 Open <Sys settings> menu item. Only applies to pedelecs with this equipment 2 Open <24h form (24h time format)> sub-menu 1 Open <My eBike> menu item. item. 2 Open <eShift> sub-menu item. 3 Follow the instructions on the on-board computer.
Page 140: Resetting The Range
Operation 6.5.18 Connect external devices 6.5.17.26Resetting the range 1 Open <My eBike> menu item. 6.5.18.1 Switching on Bluetooth® 2 Open <Range> sub-menu item. 1 Open <Bluetooth®> menu item. 3 Follow the instructions on the on-board 2 Follow the instructions on the on-board computer.
Page 141: 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 142: 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 143: Mobile Holder
Operation 6.6.3 Mobile holder Only applies to pedelecs with this equipment A holder for SP Connect mobile case is fitted to the stem.  Observe the operating instructions for the mobile and the SP Connect mobile case.  Use on tarmacked roads only. ...
Page 144: Personal Protective Equipment And Accessories For Road Safety
Operation 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. 8 The clear sounding bell must be fitted and must work.
Page 145: Straightening The Quickly Adjustable Stem
Operation Straightening the quickly 6.10 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 146: Raising The Kickstand
Operation 6.13 Using the pedals  The ball of the foot is placed on the pedal when riding and pedalling. Figure 163: The maximum load bearing (1) capacity is indicated on the pannier rack.  Never exceed the maximum permitted total weight when packing the pannier.
Page 147: Using The Battery
Operation 6.16 Using the battery  Switch off the battery and the drive system before 6.16.2 Pannier rack battery removing or inserting the battery. Only applies to pedelecs with this equipment 6.16.2.1 Removing the pannier rack battery 6.16.1 Frame battery Only applies to pedelecs with this equipment 6.16.1.1 Removing the frame battery Figure 166: Removing (2) and inserting (3) the pannier...
Page 148: Integrated Battery
Operation 6.16.3 Integrated battery Only applies to pedelecs with this equipment 6.16.3.1 Removing the integrated battery 6.16.3.2 Inserting the integrated battery Figure 168: Inserting the integrated battery Figure 167: Removing the integrated battery 1 Place the battery into the integrated battery 1 Open battery lock with battery key (1).
Page 149: Charging The Battery
Operation 6.16.4 Charging the battery 6.16.5 Charging the dual battery  The ambient temperature during the charging Only applies to pedelecs with this equipment process must be within the range from 0 °C to 40 °C. Notice  The battery can remain on the pedelec or can be removed for charging.
Page 150: Using Double Battery Model With A Single Battery Only
Operation 6.16.6 Using double battery model with a single battery only One of the charging sockets is not accessible or is sealed with an end cap on pedelecs with two batteries. Figure 169: Covering open contacts with cover cap – example: pannier rack battery ...
Page 151: Using Pedelec With The Electric Drive System
Operation 6.17 Using pedelec with the electric drive system 6.17.1 Switching on the electric drive system system As soon as you stop pushing the pedals in normal mode or reach a speed of 25 km/h, the drive CAUTION system switches off the assistance system. The assistance system starts up again when you push the pedals and your speed is less than 25 km/h.
Page 152: On-Board Computer
Operation 6.18 On-board computer 6.18.2 Switching on the on-board computer Notice  Never use the on-board computer as a handle. The on-board computer may become irreparably damaged if you use it to lift the pedelec. Figure 171: Position of On-Off button (control panel) ...
Page 153: Using The Usb Port
Operation 6.18.4 Using the USB port 6.18.5 Using the riding light Notice A USB connection is not a waterproof plug connection. Any moisture penetrating through the USB port may trigger a short circuit in the on- board computer.  Never connect an external device when cycling in the rain.
Page 154: Using The Push Assist System
Operation 6.18.6 Using the push assist system 1 Press the push assist button briefly. CAUTION  The push assist is activated. 2 Press and hold the plus button within three Injury from pedals or wheels seconds. The pedals and the drive wheel turn when the ...
Page 155: Selecting The Level Of Assistance
Operation 6.18.7 Selecting the level of assistance  The control panel is used to set how much the electric drive should assist the rider when pedalling. You can change the level of assistance at any time when you are cycling. Figure 174: Position of plus and minus buttons ...
Page 156: Brake
Operation 6.19 Brake 6.19.1 Using the brake lever Only applies to pedelecs with this equipment 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.
Page 157: Suspension And Damping
Operation 6.20 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 158: Adjusting The Suntour Compression Adjuster
Operation 6.20.1 Adjusting the Suntour compression adjuster Figure 177: Suntour compression adjuster in open (1) and closed (2) position  Place compression adjuster in the OPEN position.  The compression adjuster is open.  Place compression adjuster in the LOCK position.
Page 159: Adjusting The Rockshox Compression Adjuster
Operation 6.20.1.1 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 178: Changing compression adjuster to a harder setting ...
Page 160: Gear Shift
Operation 6.21 Gear shift The selection of the appropriate gear is a Lever A switches from a smaller pinion to a larger prerequisite for a physically comfortable ride and one. The number of pinions switched depends on making sure that the electric drive system the selected position of lever A.
Page 161: Using An Enviolo Gear Shift Gear
Operation 6.21.2 Using an ENVIOLO gear shift gear Only applies to pedelecs with this equipment The selection of the appropriate gear is a The hub cannot be switched through its entire prerequisite for a physically comfortable ride and transmission range when stationary. As a general making sure that the electric drive system rule, 50–70% of the transmission range can be functions properly.
Page 162: Switching Gear Manually
Operation 6.21.3.1 Switching gear manually Changing down Switch to a low transmission ratio for setting off or driving uphill.  Turn the twist grip backwards.  A hill is shown on the display. Figure 183: Hill display (1) when changing down (2) Change up Switch to a high transmission ratio for higher speeds.
Page 163: Using A Shimano Hub Gear
Operation 6.21.4 Using a SHIMANO hub gear Only applies to pedelecs with this equipment CAUTION Crash caused by incorrect use If the rider applies too much pressure on the pedals during a gear change and activates the shifter or changes several gears at a time, their feet may slip from the pedals.
Page 164: Using Eshift
Operation 6.21.5 Using eShift 6.21.5.2 eShift with manual SHIMANO DI2 hub gears eShift refers to the integration of electronic gear Only applies to pedelecs with this equipment shift systems into the electric drive system. The new gear is shown briefly on the on-board 6.21.5.1 eShift with SHIMANO DI2 automatic hub computer each time it is changed.
Page 165: Parking
Operation 6.22 Parking Check list after each ride Notice Cleaning Heat or direct sunlight can cause the tyre pressure  Lights and reflectors section 7.2.5 to increase above the permitted maximum  Brake section 7.2.5 pressure. This can destroy the tyres. ...
Page 166: Screwing In The Quickly Adjustable Stem
Operation 6.22.1 Screwing in the quickly adjustable stem Only applies to pedelecs with this equipment Screw in the All Up stem to save space when 3 Turn handlebars 90° in a clockwise direction. parking. 1 Open stem clamping lever. Figure 186: Example of All Up with open stem clamping lever Figure 188: Example of All Up screwed in 2 Pull handlebars into highest possible position.
Page 167: Activating The Lock Function
Operation 6.22.2 Activating the lock function Only applies to pedelecs with this equipment  Remove the on-board computer used during set-up.  The lock function is activated. The drive system now provides no assistance. However, the rider can continue to use the pedelec without assistance.
Page 168: 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 169 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 170 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 171 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 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178: 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 179: 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 180: 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 181: 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 182: 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 190: Lubricating the chain...
Page 183: 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 184: 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 185 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 6.5.8).
Page 186: 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 187: 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 188: 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 189: 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 190: Checking The Back-Pedal Brake
Cleaning and servicing 7.5.2.5 Checking the back-pedal brake Only applies to pedelecs with this equipment  There are sharp corners and edges on the back- pedal brake. Wear gloves. 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube. ...
Page 191: Checking The Rim Brake
Cleaning and servicing 7.5.2.6 Checking the rim brake Only applies to pedelecs with this equipment Checking the brake linings Checking the rim braking surface for wear  We recommend that you also replace the rims The side wall is more prone to wear in rim brakes. at the same time as every second brake lining The wear depends on the stress loads during replacement.
Page 192: 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 193: 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 194: 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 195: 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 196: 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 197: 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 198 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 199 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 200: 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 201: 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 202 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 203 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 204 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 205 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 206 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 207 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 208: 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 209: 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 210: 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 211: 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 212: 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 213: 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 214: 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 215 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 215: Removed spring washer Figure 213: Pulling the end cap out 2 Carefully remove the wiper from the groove.
Page 216 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 217 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 218 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 219 Maintenance 9 Carefully insert slide bushing tube into the seat tube. Figure 240: Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper. Figure 237: Inserting the slide bushing tube into the seat tube 10 Place outer sleeve on the seat tube and push downwards firmly.
Page 220: 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 221 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 251: Removing the wiper Figure 255: inserting and fastening the wiper 5 Use a small, sharp object to look for and remove the end of the felt ring.
Page 222 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 256: Cleaning the slide bushing tube Figure 259: Cleaning the longitudinal groove Notice 4 Apply grease into the longitudinal groove and on both cross-pieces.
Page 223 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 224: 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 225: 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 226: Troubleshooting, Fault Clearance And Repair
Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Troubleshooting and fault 9.1.2 Error message clearance If an error message is displayed, run through the following actions: The components of the drive system are constantly checked automatically. If an error is 1 Make a note of the system message.
Page 227: Errors In The Assistance Function
Troubleshooting, fault clearance and repair 9.1.3 Errors in the assistance function Symptom Cause Remedy Check battery is charged. Is the battery charged sufficiently? Recharge the battery if it is almost flat.  Press On-Off button (battery). Is the system switched on? ...
Page 228: Battery Errors
Troubleshooting, fault clearance and repair 9.1.4 Battery errors Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace old battery with new one. quickly. useful life. Disconnect the charger mains plug and plug it in again. Is the charger mains plug firmly Start charging.
Page 229: On-Board Computer Errors
Troubleshooting, fault clearance and repair Symptom Cause Remedy Remove from the battery immediately. There is an unusual Contact the fire service immediately. smell. Observe all the warnings in Section 2 Safety. Remove from the battery immediately. Fumes are emitted from Contact the fire service immediately.
Page 230: Other Errors
Troubleshooting, fault clearance and repair 9.1.7 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 231: Suntour Suspension Fork
Troubleshooting, fault clearance and repair 9.1.8 Suntour suspension fork 9.1.8.1 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 232: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.1.8.2 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 233: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.1.8.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. The deflection is quickly used up, body weight shifts forward and the pedelec loses some momentum. Figure 272: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 273: Changing compression adjuster to a harder setting...
Page 234: Excessively Hard Damping On Bumps
Troubleshooting, fault clearance and repair 9.1.8.4 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 235: Rockshox Suspension Fork
Troubleshooting, fault clearance and repair 9.1.9 RockShox suspension fork 9.1.9.1 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 236: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.1.9.2 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 237: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.1.9.3 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 280: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 281: Changing compression adjuster to a harder setting...
Page 238: Excessively Hard Damping On Bumps
Troubleshooting, fault clearance and repair 9.1.9.4 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 239: Rear Frame Damper
Troubleshooting, fault clearance and repair 9.1.10 Rear frame damper 9.1.10.1 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 240: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.1.10.2 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 241: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.1.10.3 Suspension too soft on inclines The rear frame damper deflects deeply through the rider's weight shifts forward and the bicycle the deflection range Deflection is quickly used up, loses some momentum. Figure 288: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 289: Suntour compression adjuster (1) on the rear frame damper...
Page 242: Excessively Hard Damping On Bumps
Troubleshooting, fault clearance and repair 9.1.10.4 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 243: Rockshox Rear Frame Damper
Troubleshooting, fault clearance and repair 9.1.11 RockShox rear frame damper 9.1.11.1 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 244: Rebounding Too Slowly
Troubleshooting, fault clearance and repair 9.1.11.2 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 245: Suspension Too Soft On Inclines
Troubleshooting, fault clearance and repair 9.1.11.3 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 296: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 297: Position and shape of the compression adjuster (blue) depends on the model ...
Page 246: Excessively Hard Damping On Bumps
Troubleshooting, fault clearance and repair 9.1.11.4 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 247: Repair
Troubleshooting, fault clearance and repair Repair Special expertise and tools are required for many 9.2.4 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 248: Replacing Pedelec Components If Lock Function Is Installed
Troubleshooting, fault clearance and repair 9.2.5 Replacing pedelec components if lock function is installed 9.2.5.1 Replacing a smartphone 1 Install Bosch eBike connect app on the new smartphone. 2 Log on using the same account which was used to activate the lock function. 3 Connect on-board computer with the smartphone while the on-board computer is in use.
Page 249: 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 250 Recycling and disposal Waste type Disposal Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer Electric devices: Take to a municipal collection point for electronic waste Motor Display Control panel Wiring Dispose of Waste oil Never mix different oil fluids. Store in original container. Cleaning cloths daubed in oil Lubrication oil Small quantities (usually <30 kg)
Page 251: 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 252 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 253: 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 254 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 255 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 256 Notes MY22K01 - 32_1.0_26.08.2021...
Page 257: Parts List
Documents 11.3 Parts list 11.3.1 Quadriga Duo CX5 KB146-xxFD, KB146-xxFW Frame … Aluminium Fork SR SUNTOUR, XCR34, Air Deflection 100 Damper … … Steering headset ACROS, AZF-584, 1.5 inch Handlebars COMPETITION, SL Trekking Handlebar width: 640 mm Handles ERGON, GP1 …...
Page 258 Documents Stand/stand mount URSUS, Wave … Motor BOSCH, Performance Line CX 250 Watt, 85 Nm Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 259: Quadriga Duo Cx10
Documents 11.3.2 Quadriga Duo CX10 KB145-xxKW Frame … Aluminium Fork SR SUNTOUR, XCR34, Air Deflection 100 Damper … … Steering headset ACROS, AZF-584, 1.5 inch Handlebars COMPETITION, SL Ergo Handlebar width: 620 mm Handles ERGON, GC1 … Stem ERGOTEC®, Barracuda …...
Page 260 Documents Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 261: Quadriga Duo Cx12
Documents 11.3.3 Quadriga Duo CX12 KB128-xxKD, KB128-xxKW Frame … Aluminium Fork SR SUNTOUR, XCR34, Air Deflection 100 Damper … … Steering headset ACROS, AZF-625, 1.5 inch Handlebars NOIR, MTB 15° Handlebar width: 680 mm; handlebar angle: 15° Handles ERGON, GP1 …...
Page 262 Documents Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 263: Quadriga Duo Cx12 Fs
Documents 11.3.4 Quadriga Duo CX12 FS KB131-xxKD Frame … Aluminium Fork ROCKSHOX, ZEB Select, Air Deflection 150 Damper ROCKSHOX, Deluxe Select … Steering headset ACROS, No.1B, 1-1/8 inch Handlebars SATORI, Riser Bar 6066 Handlebar width: 740 mm Handles ERGON, GA3 …...
Page 264 Documents Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 265: Quadriga Duo Cx12 Fs Suv
Documents 11.3.5 Quadriga Duo CX12 FS SUV KB138-xxKD Frame … Aluminium Fork SR SUNTOUR, Zeron35 boosting, Air Deflection 150 Damper ROCKSHOX, Deluxe Select … Steering headset ACROS, AZF-580, 1-1/8 inch Handlebars ERGOTEC®, Low Riser Ray 35 Handlebar width: 780 mm Handles ERGON, GP1 …...
Page 266 Documents Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 267: Quadriga Duo E-Tr Belt
Documents 11.3.6 Quadriga Duo E-TR Belt KB129-xxFD, KB129-xxFW Frame … Aluminium Fork SR SUNTOUR, XCR34, Air Deflection 100 Damper … … Steering headset ACROS, AZF-625, 1.5 inch Handlebars NOIR, MTB 15° Handlebar width: 680 mm; handlebar angle: 15° Handles ERGON, GP1 …...
Page 268 Documents Motor BOSCH, Performance Line CX 250 Watt, 85 Nm Rechargeable battery 2x BOSCH, PowerTube 625 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 269: Quadriga Pro Belt
… Dynamo … … Pannier rack … IRack 2 Guards SKS, Edge AL C56R … Chain guard Kettler Quadriga … Lock … … Stand/stand mount URSUS, Wave … Motor BOSCH, Performance Line CX 250 Watt, 85 Nm MY22K01 - 32_1.0_26.08.2021...
Page 270 Documents Rechargeable battery PowerTube 625 Horizontal 625 Wh Display BOSCH, Kiox, BUI330 With Kiox control panel Charger BOSCH, standard charger, BCS220 ...not available MY22K01 - 32_1.0_26.08.2021...
Page 271: Charger Operating Instructions
Documents 11.4 Charger operating instructions MY22K01 - 32_1.0_26.08.2021...
Page 272 Documents Standard Charger Fast Charger eBike Battery Charger 36-4/230 Standard Charger BCS220 0 275 007 907 Li-Ion Input: 230V 50Hz 1.5A Output: 36V Use ONLY with BOSCH Li-Ion batteries Made in PRC Robert Bosch GmbH 72757 Reutlingen Germany eBike Battery Charger 36-6/230 Fast Charger BCS250 0 275 007 918 Li-Ion...
Page 273 Documents Compact Charger %&6 MY22K01 - 32_1.0_26.08.2021...
Page 274 Documents MY22K01 - 32_1.0_26.08.2021...
Page 275 Documents MY22K01 - 32_1.0_26.08.2021...
Page 276 Documents MY22K01 - 32_1.0_26.08.2021...
Page 277 Documents MY22K01 - 32_1.0_26.08.2021...
Page 278 Documents MY22K01 - 32_1.0_26.08.2021...
Page 279 Documents MY22K01 - 32_1.0_26.08.2021...
Page 280: 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 281 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 282 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 283: 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 284: Appendix
City and trekking bicycle KB061-xxFD Quadriga Pro Belt City and trekking bicycle KB063-xxKD Quadriga Comp CX 11 City and trekking bicycle KB064-xxFD Quadriga Comp Belt Mountain bike KB089-xxKD Quadriga Town & Country C1 Mountain bike KB089-xxKW Quadriga Town & Country C2 Mountain bike...
Page 285 EN 15194:2017, Cycles – Electrically power assisted cycles – EPAC Bicycles The following other technical standards have been applied: • EN 11243:2016: Cycles – Pannier racks for bicycles – Requirements and test methods Cologne, 19/04/2021 ………………………………………………………………………………………………………………… Egbert Hageböck, Managing Director of KETTLER Alu-Rad GmbH MY22K01 - 32_1.0_26.08.2021...
Page 286: Declaration Of Conformity For Incomplete Machine
Appendix Declaration of conformity for incomplete machine MY22K01 - 32_1.0_26.08.2021...
Page 287 Appendix MY22K01 - 32_1.0_26.08.2021...
Page 288 Appendix MY22K01 - 32_1.0_26.08.2021...
Page 289: Directive Declaration Of Conformity With Red Directive
Appendix III. Directive declaration of conformity with RED Directive Robert Bosch GmbH, Bosch eBike Systems, hereby declares that the Nyon radio system (BUI350) complies with Directive 2014/53/EU and 2011/65/EU. The complete EU declaration of conformity is available online at: https://www.ebike-connect.com/conformity. The on-board computer features separate internal antennas for Bluetooth, WLAN and GPS with a power output.
Page 290: Keyword Index
Keyword index Keyword index Bowden cable 32 Chain wheel, 37 Brake arm, 34 Chain wheels, ABS, Brake booster 34 - cleaning, 176 Technical data 66 Brake cable, 32 Chain, 27, 37 Air valve, 43 Brake calliper, 33 – caring for, 181 Articulated shaft, Brake disc, 33 - cleaning, 177...
Page 291 Keyword index - cleaning, 175 Factory settings, Pannier rack battery, - resetting 56, 139 Language, - removing, 146, 147, 148 Fork end, 29, 43 - selecting 56, 137, 139 Pannier rack, Fork leg 29 Leather handle, – caring for, 179 Fork lock, –...
Page 292 Keyword index Seat post, 36 – caring for, 180 Unit, - cleaning, 175 - changing 56 Securing hook, 50 USB port, Serial number, - using, 152 Display 56 Service date, Valve, 30 Display 56 Dunlop valve, 31 Settings, Presta valve, 31 - changing 137 Schrader valve, 31 Shifter,...

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