KEEP SAFE TO CONSULT AT A LATER DATE Translation of original operating instructions for ZEMO pedelecs with BOSCH Intuvia on-board computer S U - E FS 1 2 , Z E 1 0 , Z E 5 F, Z E 5 F P l u s , Z E 5 R , Z E 5 R P l u s 21-17-3 234 …21 -17 -32 37, 22 -15 -20 57…22- 15- 206 2...
Contents Contents About these operating instructions Manufacturer Laws, standards and directives Language For your information 1.4.1 Warnings 1.4.2 Markups Aim of the operating instructions Type number and model Frame number Identifying the operating instructions Safety Residual risk 2.1.1 Risk of fire and explosion 2.1.2 Electric shock 188.8.131.52...
Handbrake 3.4.6 Fork lock 184.108.40.206 SR Suntour 3.4.7 Battery level indicator (battery) 220.127.116.11 Battery level indicator (battery) Technical data 3.5.1 Pedelec 3.5.2 Emissions 3.5.3 BOSCH Intuvia on-board computer 3.5.4 USB port 3.5.5 BOSCH Performance Line CX motor MY22Z01 - 12_1.0_25.07.2022...
Checking the battery 5.3.2 Preparing the battery 18.104.22.168 Retrofitting the PowerTube adapter 22.214.171.124 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 126.96.36.199 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 188.8.131.52 Securing the PowerTube BS2 battery mount 5.3.3 Preparing the wheel 5.3.4...
Contents 184.108.40.206 Adjusting the saddle tilt 220.127.116.11 Checking saddle stability 6.5.4 Handlebars 18.104.22.168 Replace handlebars 22.214.171.124 Adjusting the handlebar width 126.96.36.199 Adjusting the hand position 188.8.131.52 Adjusting the handlebars 6.5.5 Stem 184.108.40.206 Replacing the handlebars 220.127.116.11 Adjusting the handlebar height with quick release 18.104.22.168 Checking the stem stability 22.214.171.124...
Contents Before each ride Straightening the quickly adjustable stem 6.10 Using the pannier rack 6.11 Raising the kickstand 6.12 Using the saddle 6.12.1 Using the leather saddle 6.13 Using the pedals 6.14 Using the bell 6.15 Using the handlebars 6.15.1 Using multi-position handlebars 6.15.2 Using bar ends...
Contents 7.1.2 Checking the frame 7.1.3 Checking the fork 7.1.4 Checking the rear frame damper 7.1.5 Checking the pannier rack 7.1.6 Checking the mudguards 7.1.7 Check wheel concentricity 7.1.8 Checking the quick releases 7.1.9 Checking the suspension seat post 7.1.10 Checking the bell 7.1.11 Checking the handles...
Contents 7.4.10 7.4.11 Leather saddle 7.4.12 7.4.13 Spoke nipples 7.4.14 Gear shift 126.96.36.199 Rear derailleur articulated shafts and jockey wheels 188.8.131.52 Shifter 7.4.15 Pedal 7.4.16 Caring for the chain 184.108.40.206 Caring for the chain and all-round chain guard 7.4.17 Caring for the battery 7.4.18 Caring for the brake 220.127.116.11...
Contents 7.5.19 Checking kickstand stability Inspection and maintenance Initial inspection Major inspection Component-specific maintenance Carry out initial inspection Inspection and maintenance instructions 8.5.1 Inspecting the frame 18.104.22.168 Inspect the carbon frame 8.5.2 Inspecting the pannier rack 8.5.3 Inspect and maintain rear frame damper 8.5.4 Inspect gear hub 22.214.171.124...
Contents 126.96.36.199 Excessively hard damping on bumps 9.1.14 Other errors Repair 9.2.1 Original parts and lubricants 9.2.2 Repairing the frame 188.8.131.52 Removing paint damage on frame 184.108.40.206 Removing damage from impact on the carbon frame 9.2.3 Repairing the suspension fork 220.127.116.11 Removing paint damage on the fork 18.104.22.168...
About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and actions. ZEG Zweirad-Einkaufs-Genossenschaft eG You will find three categories of warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany Tel.: +49 221 17959 0 WARNING Fax: +49 221 17959 31...
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.
About these operating instructions Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part stamped on it (see Figure 2). The frame number of pedelecs with the type numbers: can be used to associate the pedelec with the Type no.
Safety Safety Residual risk Pedelecs pose the following residual risks: Never use incorrect charger • Risk of fire and explosion Chargers with excessive voltage damage • Electric shock batteries. This may cause a fire or an explosion. • Risk of a crash ...
Safety Storing faulty batteries Avoid overheating in the charger Your specialist dealer will dispose of faulty The charger heats up when charging the battery. batteries. If the battery is not allowed to cool down sufficiently, it can cause a fire or burns to the ...
Safety 2.1.2 Electric shock 22.214.171.124 Incorrect tightening torque If a screw is fastened too tightly, it may break. If a 126.96.36.199 Damage screw is not fastened enough, it may loosen. This Damaged chargers, cables and plug connectors will cause a crash with injuries. increase the risk of electric shock.
Safety Toxic substances 2.2.2 Toxic substances If substances are released or used which pose a risk to people and the environment, effective protective measures must be taken. Toxic substances (also known as poison or toxins) refer to substances which can cause damage to Possible hazards, contamination and health living beings if they enter the organism above a hazards due to:...
Safety Personal protective equipment Defective battery Liquids and vapours may leak from damaged or Wear a suitable helmet. The helmet must have faulty batteries. Excessively high temperatures a reflective strip or a light in a clearly visible may also cause liquids and vapours to leak from colour.
Safety Safety markings and safety What to do in an emergency instructions 2.8.1 Dangerous situation in road traffic Pedelec and battery nameplates contain the following safety markings and safety instructions: If you encounter any hazards or dangers in road traffic, apply the brake until the pedelec comes to a halt.
Safety After contact with eyes After skin contact 1 Rinse eyes under flowing water for at least ten 1 Remove any solid particles immediately. minutes with the lids open; also rinse under 2 Remove contaminated clothing immediately. lids. 3 Rinse the affected area with plenty of water for 2 Immediately consult a doctor in case of any at least 15 minutes.
Description Description Proper use All checklists and instructions for actions in these regulations for the prevention of accidents and operating instructions met. Approved accessories environmental protection in the respective country 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.
Description 3.1.1 Improper use Failure to adhere to the proper use poses a risk of • lending the pedelec to untrained pedelec rider • carrying other people personal injury and material damage. It is • riding with excessive baggage prohibited to use the pedelec in the following •...
Description 3.1.2 Permitted total weight (PTW) The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is • the weight of the fully assembled pedelec • plus body weight • plus baggage Type no.
Description 3.1.3 Environmental requirements You can be ride the pedelec within a temperature Temperatures under -10 °C and over +60 °C must range between -5 °C and +40 °C. The electric be avoided as a general rule. Never put the drive system is limited in its performance outside battery in a car in summer or store it in direct this temperature range.
Description The pedelec is unsuitable for the following areas of use: Child's City and bicycles/ Area of use trekking Mountain bikes Racing bicycle Cargo bike Folding bicycle bicycles for bicycles young adults Never drive off- Never drive off- Never drive off- Never drive off- Never drive off- road or perform...
Description Nameplate The nameplate is situated on the frame. The exact The nameplate contains thirteen pieces of position of the nameplate is described in Figure 3. information. ZEG Zweirad-Einkaufs- Genossenschaft eG Longericher Str. 2 50739 Köln, Germany Typ: 22-17-1017 EPAC nach EN 15194 0,25 kW / 25 km/h...
Description Components 3.3.1 Overview 22 23 24 Figure 3: Pedelec viewed from right, Bull Cross Rider EVO 2 used as example Front wheel Seat post Chain Front wheel hub Saddle Frame number Fork Pannier rack Chain guard Front wheel mudguard Reflector Motor Front light...
Description 3.3.2 Chassis The chassis comprises two components: • Frame and • steering system 188.8.131.52 Frame The frame absorbs all forces which act on pedelec from body weight, pedalling and the ground. The frame also acts as a carrier for most components. The frame geometry determines the pedelec’s ride performance.
Description 184.108.40.206 Handlebars 220.127.116.11 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.
Description 3.3.3 Suspension Both forks and suspension forks are fitted in this model series. 18.104.22.168 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 Figure 8: Without suspension (1) and with suspension (2) than pedelecs with suspension.
Description Negative deflection (sag) Negative deflection (sag) is the percentage of speed if it is optimally adjusted. The wheel stays total deflection that is compressed by body in contact with the ground when passing over weight, including equipment (such as a bumps (blue line).
Description Rebound damping Rebound damping defines the speed at which the speeds also increase. Rebound damping needs to suspension rebounds after being loaded. be increased to achieve an optimal setting if the Rebound damping controls the suspension fork air pressure or spring stiffness is increased. The extension and rebound speed, which, in turn, has damper rebounds at a controlled speed if the fork an impact on traction and control.
Description Steel suspension fork structure Air suspension fork structure The stem and the handlebars are fastened to the The air suspension fork comprises up to three fork steerer. The wheel is fastened to the axle. assembly groups: • Air suspension assembly (orange) •...
Description 3.3.4 Wheel Tyre pressure The permitted pressure range is indicated on the side of the tyre. It is indicated in psi or bars. The tyre is only able to support the pedelec if there is adequate tyre pressure. The tyre pressure must be adjusted to the body weight and then checked on a regular basis.
Description Carcass Tread with profile The carcass is the tyre’s supporting structure. A rubber tread is attached to the exterior of the There are usually three carcass plies beneath the carcass. tread. The carcass comprises a webbing with The tread has little influence on riding characteristics threads, usually made of polyamide (nylon).
Description Bead core Puncture protection belt Tyre carcasses are wrapped around bead cores. There may be a puncture protection belt between Wrapping the carcass around both sides creates the carcass and the tread. three carcass plies. To ensure that tyres do not slip when inflated on the rim and have an effective grip, the bead cores are stabilised in two different ways: Figure 20: Effect of puncture protection belt...
Description 3.3.5 Braking system A pedelec's brake system is primarily operated 22.214.171.124 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 •...
Description 126.96.36.199 Disc brake Figure 23: 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 permanently screwed to the hub.
Description 3.3.6 Saddle 188.8.131.52 Patent seat post The purpose of the saddle is to absorb body weight, provide support and enable different riding positions. The shape of the saddle thus depends on the intended use of the pedelec and the rider’s physique and posture.
Description 184.108.40.206 Suspension seat post Suspension seat posts can reduce shock after one-time hard impacts, thus improving ride comfort significantly. However, suspension seat posts are not able to compensate for bumps in the road. If the seat post is the only suspension element, the entire pedelec is a non-suspended mass.
Description 3.3.8 Mechanical drive system The pedelec is driven by muscle power, just like a 220.127.116.11 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.
18.104.22.168 Rechargeable battery BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards. Each battery cell is protected by a steel cup and encased in a plastic battery housing.
Description Battery performance is reduced when the 22.214.171.124 Pannier rack battery temperature drops since this increases electrical Three different types of pannier rack batteries can resistance. You should expect the range to be be fitted: less than normal at low temperatures in winter. We recommend using thermal protection sleeves when riding longer distances at low temperatures.
Securing hook On-off button (battery) Battery level indicator (battery) Battery housing 126.96.36.199 Charger Each pedelec is supplied with a charger. As a general rule, any BOSCH charger may be used: • The 2A compact charger • The 4A standard charger •...
Description 3.3.11 On-board computer The pedelec has a BOSCH Intuvia on-board computer. The on-board computer controls the drive system and displays the journey data. The rider can switch off the electric drive system by removing the on-board computer. The battery powers the on-board computer if the...
Description Description of controls and screens 3.4.1 Handlebars Figure 38: Detailed view of handlebars with BOSCH Intuvia on-board computer, example Rear wheel hand brake Seat post remote control Bell Control panel Front lamp Sag setting wheel On-board computer Fork lock, lockout...
S P O R T mountainous rides and on urban roads. Constant assistance, for long-range TO U R Figure 39: BOSCH Intuvia on-board computer layout tours. Riding light button Low assistance for maximum range with maximum efficiency. Info button (on-board computer)
Description 188.8.131.52 Charge level indicator (on-board 184.108.40.206 Indicator for motor power used computer) If the motor is active, the motor power used The battery level indicator displays the pedelec indicator is shown on the on-board computer battery level, not the level for the on-board display.
Description 220.127.116.11 Journey information Applies only to eShift with SHIMANO DI2 automatic hub gears Depending on the type of pedelec, the function display may show up to seven journey information The following additional function is available on items. The displayed journey information can be the function display: switched.
Description 18.104.22.168 System settings and data 22.214.171.124 Additional system settings The system settings need to be opened to see the Applies only to eShift with SHIMANO DI2 automatic hub gears system settings and specifications. The system setting values can be changed but the system specifications can't.
Description Applies only to eShift with SHIMANO DI2 Applies only to eShift with ROHLOFF E-14 automatic hub gears Speedhub 500/14 Display Change Display Change Gear adjustment You can use this menu option to Start gear This is where you can set the start make a fine adjustment to the gear.
Description 3.4.3 Control panel The on-board computer is operated using four buttons on the control panel. Figure 42: Overview of the BOSCH control panel Info button (control panel) Push Assist button Plus button (control panel) Minus button (control panel) MY22Z01 - 12_1.0_25.07.2022...
Description 3.4.4 Gear shift 126.96.36.199 SHIMANO derailleur gears Only applies to vehicles with this equipment The gear shift is on the right of the handlebars. SHIMANO SL-M3100 gear shift The gear shift has one or two shifters. SHIMANO SL-M315 gear shift Figure 44: Example of SHIMANO SL-M3100 Shifter A Shifter B (optional)
Description 3.4.5 Handbrake There is a handbrake on the left and right of the handlebars. Figure 45: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example The left handbrake (2) controls the front wheel The right handbrake (1) controls the rear wheel brake.
Description 3.4.6 Fork lock Only applies to vehicles with this equipment The suspension in suspension forks is adjusted 188.8.131.52 SR Suntour using fork locks. The fork locks are either directly The following (compression dampers) may be on the suspension fork or can be controlled using featured on the suspension fork: the remote control on the handlebars.
Description 3.4.7 Battery level indicator (battery) Each battery has its own level indicator: 184.108.40.206 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%...
Permitted charging temperature 0… 40 °C Operating temperature -5… +40 °C range Storage temperature -10… +40 °C Table 34: Technical data for BOSCH PowerTube 625, BBP282 and BBP283 vertical batteries Charging temperature 0… +40 °C 3.5.7 Bicycle lighting Protection class...
Description SHIMANO, SLX SL-M7100 Attachment screw 3 Nm 4 mm hex bit SHIMANO XTR SL-M9100 3 Nm 4 mm hex bit Attachment screw 220.127.116.11 Rear derailleur SHIMANO for MTB/trekking 8–10 Nm Hex key, 5 mm Attachment screw, standard type SHIMANO for MTB/trekking 3–4 Nm Hex key, 5 mm Attachment screw with bracket...
Description 18.104.22.168 Handlebars Clamping screw, conventional 5 … 7 Nm* CONTROL TECH, handlebar clamp 14 … 16 Nm with one or two screws SHIMANO, handlebar clamp with one 20 … 29 Nm or two screws 22.214.171.124 Stem FSA, carbon quill stem, 9 Nm 15 mm spanner 126.96.36.199...
Description 188.8.131.52 Brake cable SHIMANO 5–7 Nm Screw wrench, 8 mm Connecting screw, handbrake SHIMANO 5–7 Nm Hex key, 3 mm 8–10 Nm Hex key, 4 mm Connecting screw, brake calliper, version for banjo type connection SHIMANO 5–7 Nm Hex key, 3 mm Connecting screw for brake calliper, straight version SHIMANO for racing bicycles...
Description 184.108.40.206 Cantilever brake SHIMANO 5–7 Nm Hex key, 5 mm Brake caliper attachment screw SHIMANO 8–9 Nm Hex key, 5 mm Screw wrench, 10 mm Attachment screw for brake shoe SHIMANO 6–8 Nm Hex key, 5 mm Bowden cable attachment screw 220.127.116.11 Chainring …...
Description 18.104.22.168 Headlight FUXON headlight Attachment screw >5 Nm SUPERNOVA, M99 Pure/Pure+, V521s Attachment screw 2 Nm M6 attachment screw, self-locking nut, washer SUPERNOVA, M99 Pure/Pure+, V521s Stem screw 6 Nm *if there is no other data on the component MY22Z01 - 12_1.0_25.07.2022...
Transporting and storing Transporting and storing Weight and dimensions for transportation Weight and dimensions during transportation 43 cm # 22-15-2061 48 cm # 53 cm # 43 cm # 22-15-2062 48 cm # 53 cm # 43 cm # 22-15-2059 48 cm # 53 cm # 43 cm #...
Transportation and storage Transportation 4.3.2 Transporting the pedelec Bicycle rack systems which use the handlebars or frame to hold the pedelec in an upside-down CAUTION position exert inadmissible forces on its components during transportation. This can cause Crash caused by unintentional activation the supporting parts to break.
Transportation and storage Storing Store pedelec, on-board computer, battery and Remove the on-board computer from its mount if charger in a clean, dry place where they are the pedelec is not going to be used for up to four protected from sunlight.
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.
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. ...
22.214.171.124 Retrofitting the PowerTube adapter Only applies to pedelecs with this equipment The PowerTube Adapter 400 or 500 needs to be altered to use the BOSCH PowerTube 625 battery mount. 1 Use a TORX® T25 wrench to undo the screws in the battery mount.
Assembly 126.96.36.199 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach upper interface (lock side) from the BOSCH PowerTube 625 battery with a TORX® T20 wrench. Figure 59: Pushing the battery cover onto battery ...
Assembly 188.8.131.52 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach upper interface (lock side) from the 3 Screw the battery mounting plate onto BOSCH PowerTube 625 battery with a PowerTube extension with original BOSCH TORX®...
184.108.40.206 Securing the PowerTube BS2 battery mount Only applies to pedelecs with this equipment The BOSCH PowerTube BS2 battery mount must 5 Use a 15 mm screw wrench to undo the left be secured by clamping a clip on its rear.
8 Undo rear wheel and push forwards. The belt or the chain is loosened. Figure 70: Unfastening the belt sprocket 13 Use BOSCH crank puller on a ratchet to remove the crank to the right. 14 Detach crank. 15 Unfasten belt sprocket with BOSCH removal tool on ratchet or torque wrench.
Assembly Undoing screws on battery mount 24 Use a TORX® T25 wrench to undo the screws in the battery mount. The counter nut will fall into the frame. Figure 72: Position of attachment screws (1) 20 Remove motor cover. 21 Remove cabling. Figure 75: Undoing screws on battery mount 25 Remove battery mount and turn over.
Assembly 27 Turn battery mount over and place on the aluminium brace in the frame. Position Connection Colour Voltage Headlight blue 12 V 28 Use a TORX® T25 wrench to fasten the screws Speed sensor Grey At least 3.3 V into the battery mount.
Grease belt sprocket or chain wheel. Place belt sprocket or chain wheel on the crankshaft. 36 Position crank on top. Use the BOSCH tool and a ratchet to fasten the crank to the left. 37 Fasten the crank screw with the specified torque (Section 220.127.116.11 and 18.104.22.168).
Assembly 5.3.3 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.
Assembly 5.3.4 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 22.214.171.124 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this 4 Insert the securing screw on the non-drive equipment side. ...
Assembly 126.96.36.199 20 mm cross axle Only applies to Suntour forks with this 2 Tighten the cross axle with the red handle. equipment CAUTION Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
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 96: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Assembly 188.8.131.52 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.
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 leg length: 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...
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.
Assembly 5.3.7 Checking the stem and handlebars 184.108.40.206 Checking the connections 220.127.116.11 Checking the bearing clearance 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.
Operation Operation Risks and hazards WARNING WARNING Injuries and death caused by distraction Injuries and death 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.
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.
Operation Tips for a greater range The pedelec's range depends on many Gear switching habits influencing factors. A single battery charge may only last fewer than 20 kilometres but much more Use a low gear and a low level of assistance on than 100 is also possible.
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.
Operation Code Description Method of resolution Code Description Method of resolution Configuration error Temperature error Re-start the system. Switch off the system to cool The pedelec is outside the motor and battery down Contact your specialist the permitted temper- or warm them to the dealer if the problem ature range permitted temperature...
Operation 6.3.2 Rechargeable battery Code Description Method of resolution The battery is protected against deep discharge, Error in the line to the Contact specialist rear wheel speed dealer. overcharging, overheating and short circuits by sensor Electronic Cell Protection (ECP). In the event of a Implausible signals Re-start the system.
Operation Instruction and customer service The supplying specialist dealer will provide 6.5.1 Preparing customer service. Contact details can be found on the pedelec pass for these operating instructions. The following tools are required to adjust the 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...
Operation 6.5.2 Pedelec adjustment procedure Observe the correct order for adjustment. For pedelecs with components only Sequence Adjustment Section Saddle • Straighten saddle 18.104.22.168 • Adjust saddle height 22.214.171.124 • Adjust saddle position 126.96.36.199 • Adjust saddle tilt 188.8.131.52 Handlebars 6.5.4 Stem...
About these operating instructions 6.5.3 Determining the sitting position The starting point for a comfortable posture is the Position on roadster Position on city bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.
Operation 184.108.40.206 Straighten saddle 220.127.116.11 Positioning the saddle with eightpins suspension seat post Position saddle in direction of travel. In doing Only applies to pedelecs with this equipment so, align the tip of the saddle with the top tube. 1 Position saddle in direction of travel.
Operation 18.104.22.168 Adjusting the saddle height 5 Open the quick release on the seat post to change the seat height (1). To do so, push the To adjust the saddle height safely, either: clamping lever away from the seat post (3). •...
Operation 22.214.171.124 Setting the saddle height with the remote control Use the seat height formula to set the saddle height: Seat height (SH) = inner leg length (I) × 0.9 Notice If you are unable to achieve the required saddle height, the seat post must be lowered further into the seat tube.
Operation 126.96.36.199 Adjusting the saddle position 188.8.131.52 Adjusting the saddle tilt The saddle can be shifted on the saddle frame. The saddle tilt must be adjusted to the seat height, The right horizontal position ensures an optimal the saddle and handlebar position, and the saddle leverage position for legs.
Operation 6.5.4 Handlebars 184.108.40.206 Replace handlebars 220.127.116.11 Adjusting the hand position The hand is an optimal position on the handlebars Not included in price when the forearm and hand are in a straight line, i.e. the wrist is not bent. In this way, the nerves are Handlebars are components that may be §...
Operation 18.104.22.168 Adjusting the handlebars The handlebars and their position determine the posture that the pedelec rider adopts on the pedelec. 1 After selecting the riding position (see Section 22.214.171.124), determine the angle of the upper body and upper arm. 2 Pre-tension the back muscles when adjusting the handlebars.
Operation 6.5.5 Stem 126.96.36.199 Replacing the handlebars 188.8.131.52 Checking the stem stability Hold handlebars firmly after adjusting the Not included in price saddle. Press full body weight on the Handlebar-stem units are components that may handlebars. § be replaced after approval by the vehicle or parts ...
Operation 184.108.40.206 Setting the quill stem 220.127.116.11 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.
Operation 18.104.22.168 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 120: 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).
Operation 6.5.6 Handles 22.214.171.124 Replacing the handles 126.96.36.199 Adjusting ergonomic handles Only applies to pedelecs with this equipment Not included in price Handles with bolt clamps are components which § may be replaced without approval. If there is pain or numbness in the index, middle finger or thumb, this may be due to excessive pressure on the exit of the carpal tunnel.
Operation 6.5.7 Tyres 188.8.131.52 Adjust tyre pressure Tyre pressure in bar for body weight The correct tyre pressure largely depends on the Tyre width approx. approx. approx. weight load on the tyres. This load is determined 60 kg 80 kg 110 kg by the weight of the pedelec, the rider’s body 25 mm...
Operation 184.108.40.206 Replacing tyres Not included in price Tyres are components that may be replaced after § approval by the vehicle or parts manufacturer. Different tyres need to be used when the area of use is changed, more weight or greater puncture protection is added, and greater acceleration or more dynamic cornering is used.
Operation 6.5.8 Brake The handbrake grip distance can be adjusted to 220.127.116.11 Change handbrake inclination 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 pedelec are connected to the thumb and the index and rider’s preferences.
Operation 2 Set the brake lever angle as indicated in the 18.104.22.168 Determining the grip distance table. 1 Measure hand size using the grip distance gauge. Saddle-handlebar height Brake angle difference (mm) 2 Adjust the grip distance at the pressure point >10 20°…25°...
Operation 22.214.171.124 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 (–).
Operation 126.96.36.199 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.
Operation 188.8.131.52 Replacing brakes Not included in price Brake components may only be replaced with § original components. In the case of disc brake pads, the optimum pad compound may be adapted to the surface and the rider’s experience. 184.108.40.206 Retracting the brake linings Disc brakes require wearing-in time.
Operation 6.5.9 Gear shift Adjust the position of the gear shift to the pedelec 220.127.116.11 Replacing the gear shift riders’ needs. Not included in price 1 Undo attachment screw. All gear shift components (rear derailleur, shifter, 2 Place control panel or shifter into the position §...
Operation 6.5.10 Suspension A pedelec’s fork suspension and rear frame All suspension components (rigid and damper suspension can be adjusted to the rider's § suspension forks and rear frame dampers) are weight in up to six increments, depending on the parts which may be replaced after approval by suspension system.
Operation 18.104.22.168 Adjusting the SR 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 132: Sag setting wheel (1) on the suspension fork crown ...
Operation 22.214.171.124 Adjusting the SR 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.
Operation 6.5.12 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 is increased.
Operation 126.96.36.199 Adjusting the SR SUNTOUR fork rebound damping Only applies to pedelecs with this equipment Figure 135: Example of SR SUNTOUR rebound screw (1) The fork sag is adjusted. 1 Turn the rebound screw in a clockwise direction towards the closed position until it stops.
Operation 6.5.13 Riding light Example 1 If the headlight is positioned too high, oncoming traffic will be dazzled. This can cause a serious accident with fatalities. Example 2 Positioning the headlight correctly can ensure that oncoming traffic is not dazzled and no-one is put at risk. Example 3 If the headlight is positioned too low, the space ahead is not illuminated to an optimum extent and the rider's vision is reduced in the dark.
Operation 188.8.131.52 Adjusting the headlight 1 Position the pedelec so that its front is facing a wall. 2 Mark the height of the headlight (1) on the wall with chalk. 3 Mark half the height of the headlight (2) on the wall with chalk.
Operation 6.5.14 Adjust on-board computer 184.108.40.206 Removing the on-board computer Push the on-board computer catch down and simultaneously push the on-board computer CAUTION forwards and out of the mount. 220.127.116.11 Attaching the on-board computer Crash caused by distraction 1 Place the on-board computer on the mount. A lack of concentration while riding increases the risk of an accident.
Operation 18.104.22.168 Charging the on-board computer 22.214.171.124 Changing the system settings battery The System settings can be displayed and changed no matter whether the on-board Notice computer is inserted in the mount or not. A few settings are only visible and changeable if the on- The on-board computer battery discharges when board computer is inserted.
Operation Accessories Not included in price CAUTION We recommend a parking stand into which either the front wheel or rear wheel can be inserted Risk of crushing due to exposed springs securely for pedelecs which do not have a The child may crush his/her fingers on exposed kickstand.
Operation 6.6.2 Trailer 126.96.36.199 Approval for trailer with Enviolo hub Only applies to pedelecs with this equipment CAUTION Only compatible bicycle trailers are approved for ENVIOLO hub gears. Crash caused by brake failure KETTLER The braking distance may be longer if the trailer is carrying excessive load.
Operation 6.6.3 Mobile holder 188.8.131.52 Approval for trailer with ROHLOFF hub Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment ROHLOFF Speedhub 500/14 A holder for SP Connect mobile case is fitted to the stem. As a basic rule, it is permitted to use a trailer in combination with the ROHLOFF SPEEDHUB 500/ ...
Operation 6.6.6 Pannier rack The specialist dealer will advise on choosing a suitable pannier rack. The specialist dealer must install the pannier rack the first time to ensure that it is safely fitted. When installing a pannier rack, the specialist dealer makes sure that the fastening mechanism is suitable for the pedelec and that all components are installed and firmly fastened.
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 pedelec safely on public roads. 8 The clear sounding bell must be fitted and must work.
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.
Operation 6.12.1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the leather to dry out and fade. Park pedelec in the shade. Always use a saddle cover. Moisture may cause the leather to detach from material beneath and mould may form.
Operation 6.15 Using the handlebars 6.15.2 Using bar ends Only applies to pedelecs with this equipment Wear heavily padded cycling gloves. This supports sensitive areas of your palms. Bar ends can be added to normal handlebars. Vary your grip position continuously while Adjustable bar ends feature a ball joint which you riding.
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 6.16.1 Frame battery 184.108.40.206 Removing the pannier rack battery Only applies to pedelecs with this equipment 220.127.116.11 Removing the frame battery Figure 150: Removing (2) and inserting (3) the pannier...
Operation 6.16.3 Integrated battery Only applies to pedelecs with this equipment 18.104.22.168 Removing the integrated battery 22.214.171.124 Inserting the integrated battery Figure 152: Inserting the integrated battery Figure 151: Removing the integrated battery 1 Place the battery into the integrated battery 1 Open battery lock with battery key (1).
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.
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 153: Covering open contacts with cover cap – example: pannier rack ...
Operation 6.17 Using pedelec with the electric drive system 6.17.1 Switching on the electric drive 6.17.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in CAUTION normal mode or reaches a speed of 25 km/h, the drive system switches off the assistance system.
Operation 6.18 Using the on-board computer 6.18.1 Using the USB port Notice CAUTION Any moisture penetrating through the USB port Crash caused by distraction may trigger a short circuit in the on-board A lack of concentration while riding increases the computer.
Operation 6.18.4 Using the push assist system 6.18.5 Using the riding light The drive system needs to be already switched CAUTION on to turn on the riding light. Press the riding light button. Injury from pedals or wheels ...
Operation 6.19 Using the brake 6.19.1 Use handbrake 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.
Operation 6.20 Use 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...
Operation 6.20.1 Adjusting the SR SUNTOUR compression adjuster Figure 156: SR 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.
Operation 6.21 Gear shift The selection of the appropriate gear is a prerequisite for a physically comfortable ride and making sure that the electric drive system functions properly. The ideal pedalling frequency is between 70 and 80 revolutions per minute. ...
Operation 6.21.2 Use 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.
Operation 6.21.3 Using eShift 126.96.36.199 Using 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 188.8.131.52 Using eShift with SHIMANO DI2 auto- computer each time it is changed.
About these operating instructions 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. ...
About these operating instructions 6.22.1 Screwing in the quickly adjustable stem Only applies to pedelecs with this equipment Screw in the quickly adjustable stem to save 3 Turn handlebars 90° in a clockwise direction. space when parking 1 Open stem clamping lever. Figure 160: Example of All Up with open stem clamping lever Figure 162: Example of All Up screwed in...
Cleaning, servicing and inspection Cleaning, servicing and inspection Clean, maintain and inspect pedelec as indicated on checklists. Complying with these cleaning instructions can increase operational reliability, reduce wear on components, extend the service life of components and ensure safety. Checklist: Before each ride Checklist: weekly tasks Check everything is sufficiently...
Cleaning, servicing and inspection Checklist: monthly tasks Checklist: monthly tasks Cleaning the battery See Section 7.3.2. Cleaning the motor See Section 7.3.3. Clean control panel See Section 7.3.1. Clean hub See Section 7.3.12. Clean on-board computer See Section 7.3.1.
Cleaning, servicing and inspection Checklist: at least every six months (or every 1,000 km) Checklist: at least every six months (or every 1,000 km) Check Bowden cables gear Servicing the stem See Section 7.4.6. See Section 184.108.40.206. shift ...
Cleaning, servicing and inspection 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 electric drive system or on the rim of a rim brake can cause the brake is activated unintentionally.
Cleaning, servicing and inspection 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.
Cleaning, servicing and inspection 7.1.9 Checking the suspension seat post 7.1.12 Checking the USB cover Deflect and let the suspension seat post If featured, check the position of the cover on the USB port on a regular basis and adjust if rebound.
Cleaning, servicing and inspection After each ride Complying with these cleaning instructions is the 7.2.4 Cleaning the pedals only way to reduce wear on components, increase the operating hours and guarantee safety. The following items should be ready for use to clean the pedelec after each ride: ...
Cleaning, servicing and inspection Basic cleaning Complying with these basic cleaning instructions 7.3.2 Cleaning the 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...
Cleaning, servicing and inspection 7.3.4 Clean Frame, fork, pannier rack, 7.3.7 Clean handles guards and kickstand 1 Clean handles with sponge, water and soapy water. 1 Soak the components with dish-washing 2 Rinse off component with water from a detergent if the dirt is thick and ingrained. watering can.
Cleaning, servicing and inspection 7.3.9 Cleaning the saddle 7.3.12 Clean hub 1 Clean the saddle with lukewarm water and a 1 Put on protective gloves. cloth dampened with soapy water. 2 Remove dirt from hub with a sponge and soapy 2 Rinse off component with water from a water.
Cleaning, servicing and inspection 7.3.15 Clean brake 7.3.18 Cleaning the chain 220.127.116.11 Clean handbrake Notice Carefully clean the handbrake with a damp, Never use aggressive (acid-based) cleaners, soft cloth. rust removers or degreasers when cleaning the chain. 7.3.16 Cleaning the brake disc ...
Cleaning, servicing and inspection Servicing Complying with these servicing instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Battery terminal grease Table 52: Required tools and cleaning agents for servicing 7.4.1 Frame Notice Figure 163: Diagram showing wear, operating hours (x) ...
Cleaning, servicing and inspection 7.4.3 Pannier rack 4 If you have a Speedlifter Twist, also apply oil to the unlocking bolt groove in the Speedlifter body. 5 Apply a little acid-free lubricant grease 1 Dry pannier rack with a cloth. between the stem quick release lever and the sliding piece to reduce the quick release lever 2 Spray pannier rack with spray wax and leave to...
Cleaning, servicing and inspection 7.4.9 Seat post 7.4.11 Leather saddle 1 Carefully preserve screw connections with wax spray. In doing so, ensure that no wax is applied to the metal contact surfaces. Standard leather care products keep leather 2 Replace the assembly paste protective layer smooth and resistant, brighten its appearance and on the metal contact surfaces on the seat post improve or replace stain protection.
Cleaning, servicing and inspection 7.4.14 Gear shift 7.4.16 Caring for the chain 18.104.22.168 Rear derailleur articulated shafts and jockey wheels Place newspaper or paper towels underneath to collect chain oil. 1 Lift rear wheel. Treat front and rear derailleur articulated 2 Turn the crank briskly in an anti-clockwise shafts and jockey wheels with Teflon spray.
Cleaning, servicing and inspection 7.4.18 Caring for the brake 22.214.171.124 Caring for the chain and all-round chain guard 126.96.36.199 Caring for handbrake Place newspaper or paper towels underneath to collect chain oil. Notice 1 Lift rear wheel. 2 Turn the crank briskly in an anti-clockwise ...
Cleaning, servicing and inspection Inspection The following tools are required for an inspection: 188.8.131.52 Checking tyre pressure Notice Gloves If the tyre pressure is too low in the tyre, the tyre Ring spanners does not achieve its load bearing capacity. The 8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm tyre is not stable and may come off the rim.
Cleaning, servicing and inspection Dunlop valve 5 Remove the bicycle air pump. Only applies to pedelecs with this equipment 6 Screw the valve cap tight. 7 Screw the rim nut gently against the rim with The tyre pressure cannot be measured on the the tips of your fingers.
Cleaning, servicing and inspection 184.108.40.206 Checking the tyres 2 Check the side walls for wear. If there are any cracks or tears, the tyre must be replaced. The tread is far less important for bicycle tyres than it is for car tyres, for example. Consequently, tyres can still be used with a worn tread with the exception of tyres on mountain bikes.
Cleaning, servicing and inspection 220.127.116.11 Checking the rims 18.104.22.168 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 ...
Cleaning, servicing and inspection 7.5.2 Checking the brake system 22.214.171.124 Checking the hydraulic brake system CAUTION 1 Pull on the handbrake 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 ...
Cleaning, servicing and inspection 126.96.36.199 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 wiggle it gently to than 2.5 mm between the brake lining and...
Cleaning, servicing and inspection 188.8.131.52 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.
Cleaning, servicing and inspection 184.108.40.206 Checking the rim brake Only applies to pedelecs with this equipment Checking the brake linings Adjusting the V-brake We recommend that you also replace the rims Check that the braking effect initiates after one at the same time as every second brake lining third of the handbrake distance is reached.
Cleaning, servicing and inspection 7.5.3 Checking the chain 2 Add the two values together to calculate the deviation. Check chain for rust, damage and chain links 3 Check the chain tension at three to four points. that are difficult to move. ...
Cleaning, servicing and inspection 220.127.116.11 Check 1 Insert gauge between two chain links on the right-hand side. There is a different wear gauge for each chain, depending on the manufacturer: Figure 177: Gauge is inserted Figure 172: Example of a KMC gauge 2 Lower gauge down to the left-hand side.
Cleaning, servicing and inspection 7.5.6 Checking the belt The tooth profile is pointed and teeth have worn thinner. Replace belt sprocket. Contact specialist dealer. 7.5.7 Checking the belt for wear Check belt for indications of wear: Figure 181: Indications of wear on a belt Figure 183: Worn tooth profile 1 Carbon tensile fibres are exposed 2 Worn webbing with visible polymer...
Cleaning, servicing and inspection With any of these methods, the tension along the 1 Open app. belt may vary slightly, so you should repeat the 2 Click on the voltage symbol. process several times. Turn the pedal a quarter 3 Click on MEASURE. after each measurement.
Cleaning, servicing and inspection 3 Press the check gauge down with just one 18.104.22.168 ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 187: Pressing the check gauge down with one finger Figure 189: Attached measuring stick 4 Take reading where line A meets line B.
Cleaning, servicing and inspection 7.5.10 Checking the riding light 1 Check the cable connections on the headlight If the headlight or rear lights do not come on, take pedelec out of service. Contact specialist and rear light for damage and corrosion and dealer.
Cleaning, servicing and inspection 7.5.11 Checking the stem 7.5.14 Checking the seat post 1 Take seat post out of the frame. The stem and quick release system must be 2 Check seat post for cracks and corrosion. inspected at regular intervals. The specialist dealer should adjust them if they require 3 Reinsert seat post.
Cleaning, servicing and inspection 7.5.15 Check gear shift 22.214.171.124 Checking the hub gear In the case of pedelecs with a hub gear or back- 1 Check that all gear shift components are free of pedal brake, the chain or the belt is tensioned by damage.
Cleaning, servicing and inspection 126.96.36.199 Checking the derailleur gears 1 Check that there is clearance between the chain tensioner and spokes. If there is no clearance or the chain scrapes against the spokes or tyres, contact your specialist dealer. 2 Check that there is clearance between the chain or rear derailleur and spokes.
Cleaning, servicing and inspection 7.5.18 Adjusting Bowden-cable-operated 7.5.19 Checking kickstand stability twist grip, 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.
Inspection and maintenance Inspection and maintenance Initial inspection Component-specific maintenance After 200 km or 4 weeks after purchase High-quality components require extra maintenance. Tasks require technical expertise, Vibrations produced while riding can cause special tools and special lubricants. The pedelec screws and springs that were tightened during may become damaged if the stipulated pedelec manufacture to settle or come loose.
Inspection and maintenance Inspection and maintenance intervals for suspension fork Inspection and maintenance intervals for seat post SR SUNTOUR suspension fork by.schulz suspension seat post Maintenance 1 Every 50 hours Maintenance After the first 250 km; every 1,500 km after ...
Inspection and maintenance Inspection and maintenance intervals for rear frame Inspection and maintenance intervals for hub damper SHIMANO 11-speed hub RockShox rear frame damper Internal oil change and maintenance 1,000 km after Service air chamber assembly Every 50 hours start of use, then ...
Inspection and 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.
Inspection and maintenance Inspection and maintenance instructions Complying with these inspection and maintenance instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Diagnosis and documentation of current status Measures if Components Frequency Description Criteria rejected...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance Once a month Cleaning … Section 7.3.7 O.K. Dirt Cleaning Once a month Care Section 7.4.8 … O.K. Untreated Talcum powder Handles before each Wear;...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance 6 months … Section 7.4.10 O.K. Untreated 6 months Wear Section 188.8.131.52 … O.K. Defective rim New rim as speci- Rims fied in the parts list Once a month Wear on brake Section...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance Once a month Cleaning … Section 7.3.8 O.K. Dirt Cleaning 6 months Care … Section 7.4.9. O.K. Untreated Assembly paste Carbon seat post 6 months Complete clean, …...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance Venting … See manufac- O.K. 50 Hours turer Cleaning … See manufac- O.K. 50 Hours turer Venting … See manufac- O.K. 200 Hours turer RockShox dropper post Complete mainte-...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance Drive/gear shift Chain/ 6 months Check for damage Check for … O.K. Damage Refasten if neces- cassette/ damage sary or replace as pinion/ specified in parts list chainring Chain guard/ 6 months...
Inspection and maintenance Measures if Components Frequency Description Criteria rejected Accept- Inspection Tests Maintenance Rejection ance Miscellaneous before each Stability Section 7.1.5 … O.K. Loose Firm ride Once a month Dirt … Section 7.3.4 O.K. Dirt Cleaning Pannier rack 6 months Servicing …...
Inspection and maintenance 8.5.1 Inspecting the frame 8.5.3 Inspect and maintain rear frame damper 1 Check frame for cracks, warping and damage Only applies to pedelecs with this equipment to the paintwork. If there are any cracks, warping or damage to the paintwork, remove the pedelec from WARNING service.
Inspection and maintenance 8.5.5 Inspecting the stem CAUTION Incorrectly fastened screws may come loose due to impact. The stem may no longer be firmly fixed Hazard for the environment due to toxic in its position as a result. This will cause a crash substances with injuries.
Inspection and maintenance 8.5.7 Inspecting axle with quick release The quick release lever is flush with the lower housing. You should be able to see slight impression on CAUTION the palm of your hand when you close the quick release lever.
Inspection and maintenance 8.5.8 Inspecting the fork 184.108.40.206 Inspect the carbon suspension fork Only applies to pedelecs with this equipment WARNING 1 Remove fork. 2 Check fork for cracks, warping and damage to Injury due to explosion the paintwork. The air chamber is pressurised. When the air 3 You need to distinguish between scratches on system in a faulty suspension fork is maintained, the paintwork and impacts if the carbon...
Inspection and maintenance 8.5.9 Inspecting the seat post 220.127.116.11 Inspect 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.
Inspection and maintenance 18.104.22.168 Inspecting and greasing BY.SCHULZ 22.214.171.124 Inspecting and greasing RS SUNTOUR suspension seat post 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.
Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Preventing pain A pedelec is a sports vehicle which promotes health. After the first few rides, you may experience sore muscles the next day. However, permanent pain should never occur during or after a ride. Medical problems may be the cause of pain.
Troubleshooting, fault clearance and repair 9.1.1 Sitting discomfort Around 50% of all pedelec riders experience Solution sitting discomfort: • Adopt an optimal riding position (see • Pressure pain in the sitting bones Section 6.5.3). • Pain in the lower back •...
Troubleshooting, fault clearance and repair 9.1.4 Pain in shoulders and nape of neck The weight of the upper body places a strain on Solution the shoulders due to the bent-forward posture. • A more upright riding position will The more stretched the position is, the more strain immediately reduce pain.
Troubleshooting, fault clearance and repair 9.1.7 Knee pain Pedelec riding is a sport that is easy on the knee Solution joints and is recommended for beginners. Very • Contact specialist dealer. Have the powerful forces are transmitted from the thigh to pedelec adjusted (see Section 6.5).
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.
Troubleshooting, fault clearance and repair 9.1.3 Assistance function errors Symptom Cause/possible source Remedy Check battery is charged. Is the battery charged sufficiently? Recharge the battery if it is almost flat. Riding up long inclines in summer Switch off the drive system. weather or riding with a heavy load for Wait a moment and then check again.
Troubleshooting, fault clearance and repair 9.1.4 Battery error Symptom Cause/possible source Remedy Replace old battery with new one. The battery discharges The battery may be at the end of its quickly. useful life. Disconnect the charger mains plug and plug it in again. Repeat charging process.
Troubleshooting, fault clearance and repair Symptom Cause/possible source Remedy Remove from the battery immediately. There is an unusual Contact the fire service immediately. smell. Observe all the warnings in Section 2 Safety. Fumes are emitted from Remove from the battery immediately. the battery.
Troubleshooting, fault clearance and repair 9.1.7 SR SUNTOUR suspension fork 126.96.36.199 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.
Troubleshooting, fault clearance and repair 188.8.131.52 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.
Troubleshooting, fault clearance and repair 184.108.40.206 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 206: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 207: Changing compression adjuster to a harder setting...
Troubleshooting, fault clearance and repair 220.127.116.11 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.
Troubleshooting, fault clearance and repair 9.1.8 Problems with freewheel Symptom Cause Remedy Cover forgotten after fitting. Contact specialist dealer. Check installation correct. Freewheel blocked. Contact specialist dealer. Measure the length of the socket. If After fitting, socket was compressed by over-tightening the quick-release axle.
Troubleshooting, fault clearance and repair 9.1.9 Problems with hub gear Symptom Cause Remedy A noise is heard when the All gear speeds except 1. pedals are turning. A noise is heard when the pedelec is pushed All gear speeds except 1. backwards.
Troubleshooting, fault clearance and repair Symptom Cause Remedy Strange noises occur when the brakes are Contact specialist dealer. applied. Rotation feels stiff during Contact specialist dealer. free rotation. Chain jumps between the gearwheels when gear is Gearwheels and/or chain worn. Contact specialist dealer.
Troubleshooting, fault clearance and repair 9.1.10 Problems with disc brakes Symptom Cause Remedy Ringing and unusual Contact specialist dealer. Fit a city or trekking tyre. Riding on asphalt with off-road tyres. sounds from disc brakes. Dirty or greasy brake disc. ...
Troubleshooting, fault clearance and repair 9.1.11 Problems with rim brakes Symptom Cause Remedy This is not a malfunction. During the first 50 km or so after Break in brakes. A rim brake’s full braking power is not produced until the replacing the brake linings, check the rims and brake linings rider has cycled several kilometres.
Troubleshooting, fault clearance and repair 9.1.12 Problems with back-pedal brake Symptom Cause Remedy Contact specialist dealer. Lubricate brake hub. Brake is too sensitive. Replace brake shoe unit. Contact specialist dealer. Replace brake shoe unit. Brake is too weak. If the problem should persist, replace the internal hub unit. The rider needs to push Contact specialist dealer.
Troubleshooting, fault clearance and repair 9.1.13 RockShox suspension fork 18.104.22.168 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.
Troubleshooting, fault clearance and repair 22.214.171.124 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.
Troubleshooting, fault clearance and repair 126.96.36.199 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 214: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 215: Changing compression adjuster to a harder setting...
Troubleshooting, fault clearance and repair 188.8.131.52 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.
Troubleshooting, fault clearance and repair 9.1.14 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.
Troubleshooting, fault clearance and repair Repair Special expertise and tools are required for many 9.2.3 Repairing the suspension fork repairs. For this reason, repairs may only be carried out at a specialist dealer. These include: 184.108.40.206 Removing paint damage on the fork •...
Troubleshooting, fault clearance and repair 9.2.4 Replacing the riding light Only use components in the corresponding power class for replacement. 9.2.5 Adjusting the headlight The headlight must be positioned so that its light beam shines on the road 10 m in front of the pedelec (see Section 6.4).
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 –...
Recycling and disposal Waste type Disposal Dispose of Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Cleaning cloths covered in biodegradable oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer.
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.
Documents 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.
Documents 11.2 Inspection and maintenance log Diagnosis and documentation of current status Date: Frame number: Components Frequency Description Criteria Measures if rejected Inspection Tests Inspection/ Accept- Rejection maintenance ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Check mount Kickstand 6 months Functional check...
Documents Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Brake system Check mount Handbrake 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.
Documents Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Electric drive system 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; remove from service, Control panel Check Functional check...
Documents 11.3 Parts list 11.3.1 SU-E FS 12 22-15-2061, 22-15-2062 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Aion 35 Evo LO-R AIR Deflection: 100 mm Damper ROCKSHOX, Deluxe Select+ …...
Documents 11.3.2 ZE 10 22-15-2059, 22-15-2060 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie 45 LOR Air Deflection: 80 mm Damper … … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong...
Documents Rechargeable battery BOSCH, Performance Line CX 85 Nm Display BOSCH, PowerTube 625 625 Wh, vertical Charger BOSCH, Intuvia with Intuvia control panel ...not available MY22Z01 - 12_1.0_25.07.2022...
Dynamo … … Pannier rack STANDWELL with I-Rack and Ortlieb Quick Look 3 mount Guards … Chain guard CURANA Aluminium Lock ABUS, Bordo 6015 … Kickstand PLETSCHER, Flex … Motor BOSCH, Performance Line CX 85 Nm MY22Z01 - 12_1.0_25.07.2022...
Documents Rechargeable battery BOSCH, PowerTube 625 625 Wh, vertical Display BOSCH, Intuvia with Intuvia control panel Charger BOSCH, standard charger ...not available MY22Z01 - 12_1.0_25.07.2022...
Documents 11.3.4 ZE 5F Plus 22-15-2057, 22-15-2058 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie 45 LOR Air Deflection: 80 mm Damper … … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong...
Documents Rechargeable battery BOSCH, Performance Line CX 85 Nm Display BOSCH, PowerTube 625 625 Wh, vertical Charger BOSCH, Intuvia with Intuvia control panel ...not available MY22Z01 - 12_1.0_25.07.2022...
Documents 11.3.5 ZE 5R 21-17-3236, 21-17-3237 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie 45 LOR Air Deflection: 80 mm Damper … … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong...
Documents Rechargeable battery BOSCH, Performance Line CX 85 Nm Display BOSCH, PowerTube 625 625 Wh, vertical Charger BOSCH, Intuvia with Intuvia control panel ...not available MY22Z01 - 12_1.0_25.07.2022...
Documents 11.3.6 ZE 5F Plus 21-17-3234, 21-17-3235 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie 45 LOR Air Deflection: 80 mm Damper … … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong...
Documents Rechargeable battery BOSCH, Performance Line CX 85 Nm Display BOSCH, PowerTube 625 625 Wh, vertical Charger BOSCH, Intuvia with Intuvia control panel ...not available MY22Z01 - 12_1.0_25.07.2022...
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.
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.
Glossary Operating instructions Seat post Source: ISO/DIS 20607:2018: part of the user Source: EN 15194:2017: component that clamps information that machine manufacturers provide the saddle (with a bolt or assembly) and connects to machine operators; it contains guidance, it to the frame. instructions and tips related to the use of the Shut-off speed machine in all its life cycle phases.
Glossary 12.1 Abbreviations Weight of the ready-to-ride pedelec Source: ZEG: the indicated weight for a ready-to- Abbreviation Meaning/derivation ride pedelec refers to the weight of a pedelec at the time of sale. The weight of each additional Anti-blocking system accessory must be added to this weight EPAC Electric power assisted cycle permitted total weight...
Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* ZEG Zweirad-Einkaufs-Genossenschaft eG Janine Otto Longericher Str. 2 c/o ZEG Zweirad-Einkaufs-Genossenschaft eG 50739 Köln, Germany Longericher Str. 2 50739 Köln, Germany The machine, pedelec types: 21-17-3236 ZE 5R, Diamant City and trekking bicycle...
Appendix Declaration of conformity for incomplete machine MY22Z01 - 12_1.0_25.07.2022...
Keyword index Keyword index Carbon seat post, Bicycle for young adults, - care for, Air valve, Bike headset, see steering Carbon suspension fork, position, headset - inspect, Articulated shaft, Bowden cable, Carcass, - care for - check, position, Axle, Brake cable, Cargo bike, position, torque,...
Keyword index Derailleur gears, Frame,- care for, Headset, see steering headset - check Freewheel, Hub gear, - use, torque, - check Dimensions, Front derailleur, Hub, Disc brake, - clean, - adjust ROHLOFF torque, torque, - care for Display Front lamp, - clean, Display battery, position...
Keyword index - clean, Rear light, - inspect, - clean Maintenance, - use, Rear wheel brake, Manufacturer, Patent seat post, Rebound adjuster, Mechanical, Pedal, position, - gear shift - care for, Rebound adjustment, Minimum insertion depth - clean, Rebound damping, marking, - fit Rebound,...
Keyword index - suspension seat post Total deflection position, Total journey duration, remote control torque, Trailer, torque, Transportation, Securing hook, Transporting, see Transporta- Shift indicator, tion position Tread, Shifter, position, - care for, Tube, - clean - replace, position, Tyre design types, torque, Tyre pressure, Shut-off speed,...