Page 1 KEEP SAFE TO CONSULT AT A LATER DATE Translation of original operating instructions for ZEMO pedelecs with BOSCH LED Remote on-board computer S U - E FS 1 2 + , Z E 1 2 + , Z E F S 1 2 + 22-15-2061 ...22-15-2066...
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 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 2.1.3...
Page 3 Handbrake Technical data 3.5.1 Pedelec 3.5.2 Emissions 3.5.3 Bicycle lighting 3.5.4 Display mount 3.5.5 LED Remote on-board computer 3.5.6 BOSCH Performance Line CX motor 3.5.7 BOSCH PowerTube 750 battery 3.5.8 Saddle width 3.5.8.1 BROOKS ENGLAND 3.5.8.2 ERGON MY22Z0a - 12_1.0_25.07.2022...
Page 4 Contents 3.5.8.3 SELLE ROYAL 3.5.9 Puncture protection level 3.5.9.1 SCHWALBE 3.5.10 Torque Transporting and storing Weight and dimensions for transportation Designated handles, lifting points Transporting 4.3.1 Using the transport securing system 4.3.2 Transporting the pedelec 4.3.3 Shipping a pedelec 4.3.4 Transporting the battery 4.3.5 Shipping the battery...
Page 5 Contents 6.5.3.5 Calculating the saddle width 6.5.3.6 Selecting the saddle hardness 6.5.3.7 Adjusting the saddle hardness 6.5.3.8 Straighten saddle 6.5.3.9 Positioning the saddle with eightpins suspension seat post 6.5.3.10 Adjusting the saddle height 6.5.3.11 Setting the saddle height with the remote control 6.5.4 Riding position 6.5.4.1...
Page 6 Contents 6.5.15.1 Adjusting the SR SUNTOUR fork rebound damping 6.5.15.2 Adjusting the RockShox suspension fork 6.5.16 Adjusting the rear frame damper rebound damper 6.5.16.1 Adjusting the RockShox rear frame damper 6.5.17 Compression adjuster on rear frame damper 6.5.17.1 Adjusting the Suntour compression adjuster 6.5.17.2 Adjusting the RockShox compression adjuster 6.5.17.3...
Page 7 Contents 6.21.1.1 Adjusting the RockShox compression adjuster 6.22 Parking the pedelec 6.22.1 Screwing in the quickly adjustable stem 6.22.2 Activating the lock function Cleaning, servicing and inspection Before each ride 7.1.1 Checking the guards 7.1.2 Checking the frame 7.1.3 Checking the fork 7.1.4 Checking the rear frame damper 7.1.5...
Page 8 Contents 7.4.6 Stem 7.4.7 Handlebars 7.4.8 Handle 7.4.8.1 Rubber handles 7.4.8.2 Leather handle 7.4.9 Seat post 7.4.9.1 Suspension seat post 7.4.9.2 Carbon seat post 7.4.10 7.4.11 Leather saddle 7.4.12 7.4.13 Spoke nipples 7.4.14 Gear shift 7.4.14.1 Rear derailleur articulated shafts and jockey wheels 7.4.14.2 Shifter 7.4.15...
Page 9 Contents 7.5.15 Check gear shift 7.5.15.1 Electric gear shift 7.5.15.2 Mechanical gear shift 7.5.15.3 Checking the derailleur gears 7.5.16 Adjusting gear shift 7.5.16.1 Adjusting the ROHLOFF hub 7.5.17 Adjusting cable-operated gear shift, dual-cable 7.5.18 Adjusting Bowden-cable-operated twist grip, dual-cable 7.5.19 Checking kickstand stability Inspection and maintenance Initial inspection...
Page 10 Contents 9.1.5 On-board computer error 9.1.6 Lighting does not work 9.1.7 Problems with freewheel 9.1.8 Problems with hub gear 9.1.9 Problems with disc brakes 9.1.10 Problems with rim brakes 9.1.11 Problems with back-pedal brake 9.1.12 Other errors 9.1.13 SR SUNTOUR suspension fork 9.1.13.1 Rebound too fast 9.1.13.2...
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 Keyword index MY22Z0a - 12_1.0_25.07.2022...
Page 12 About these operating instructions Thank you for your trust! Copyright ZEMO pedelecs are premium quality bicycles. © ZEG Zweirad-Einkaufs-Genossenschaft eG 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 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...
Page 14: 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 15: Type Number And Model
About these operating instructions ype number and model Frame number These operating instructions are an integral part of pedelecs with the type numbers: Each frame has an individual frame number Type no. Model Pedelec type stamped on it (see Figure 2). The frame number 22-15-2061 SU-E FS+, Diamant City and trekking...
Page 16: Safety
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 ...
Page 17 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 ...
Page 18: Electric Shock
Safety Using the correct tightening torque 2.1.2 Electric shock If a screw is fastened too tightly, it may break. If a screw is not fastened enough, it may loosen. This will cause a crash with injuries. Never use damaged network components ...
Page 19: Malfunctions Due To Bluetooth
3, data is transferred to BOSCH eBike Systems (Robert Bosch GmbH) on the use of the Bosch drive unit, including its energy consumption and temperature, to help improve the product. You will find more information on the Bosch eBike website: www.bosch-ebike.com. MY22Z0a - 12_1.0_25.07.2022...
Page 20: Toxic Substances
About these operating instructions Toxic substances 2.2.2 Irritants and If substances are released or used which pose a corrosive risk to people and the environment, effective substances protective measures must be taken. Possible hazards, contamination and health Corrosive substances (also known as corrosives) hazards due to: destroy living tissue or attack surfaces.
Page 21: Personal Protective Equipment
About these operating instructions Personal protective equipment Safety markings and safety instructions  Wear a suitable helmet. The helmet must have a reflective strip or a light in a clearly visible Pedelec and battery nameplates contain the colour. following safety markings and safety instructions: ...
Page 22: What To Do In An Emergency
About these operating instructions What to do in an emergency After contact with eyes 1 Rinse eyes under flowing water for at least ten 2.8.1 Dangerous situation in road traffic minutes with the lids open; also rinse under lids.  If you encounter any hazards or dangers in road traffic, apply the brake on the pedelec 2 Immediately consult a doctor in case of any until it comes to a halt.
Page 23: Battery Fire
About these operating instructions After skin contact 1 Remove any solid particles immediately. 2 Remove contaminated clothing immediately. 3 Rinse the affected area with plenty of water for at least 15 minutes. 4 Then dab the affected skin gently. Do not rub dry.
Page 24: Description
Description Description Proper use All check lists and instructions for actions in these The rechargeable batteries are designed to operating instructions met. Approved accessories supply power to the pedelec motor only. Never can be installed by specialist staff. use the batteries for other purposes. Use the pedelec when it is in perfect, proper A compatible smartphone with the eBike Flow working order only.
Page 25: Improper Use
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 •...
Page 26: Permitted Total Weight (Ptw)
About these operating instructions 3.1.2 Permitted total weight (PTW) The pedelec may only be loaded to its maximum Type no. Model PTW [kg] permitted total weight (PTW). 22-18-3012 Sonic EVO TR-I Carbon 750 29" The maximum permitted total weight is 22-18-3014 Sonic EVO AM 1 750 •...
Page 27: Environmental Requirements
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.
Page 28 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...
Page 29: Nameplate
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...
Page 30: Components
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...
Page 31: Wheel
Description 3.3.2 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.
Page 32 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).
Page 33 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 8: Effect of puncture protection belt...
Page 34: Rim
Description 3.3.2.3 Rim The rim is the metal profile on a wheel which holds the tyre, tube and rim band together. The rim is joined to the hub with spokes. In rim brakes, the outer surface of the rim is used to brake.
Page 35: Hub
Description 3.3.2.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.
Page 36: Chassis
Description 3.3.3 Chassis The chassis comprises two components: • Frame and • steering system 3.3.3.1 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.
Page 37: Handlebars
Description 3.3.3.5 Handlebars 3.3.3.6 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 38: Suspension
Description 3.3.4 Suspension Both forks and suspension forks are fitted in this model series. 3.3.4.1 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 Figure 17: Without suspension (1) and with than pedelecs with suspension.
Page 39 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).
Page 40 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.
Page 41 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) •...
Page 42: Rear Frame Damper
Description 3.3.4.3 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 43 Description 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 27: Optimum rear frame damper ride performance over bumps MY22Z0a - 12_1.0_25.07.2022...
Page 44: Rockshox Rear Frame Damper
Description 3.3.4.4 RockShox rear frame damper The rear frame damper features air suspension, a compression damper and a rebound damper. Figure 28: Monarch RL as an example Threshold lever Rebound damper adjuster Air valve O-ring Scale MY22Z0a - 12_1.0_25.07.2022...
Page 45 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 46: Saddle
Description 3.3.5 Saddle 3.3.6.1 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.
Page 47: Suspension Seat Post
Description 3.3.6.2 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.
Page 48: Design Of By.schulz G2
Description 3.3.7 Design of by.Schulz G2 The Parallelogram suspension seat post was impacts, such as those occurring while riding developed to provide maximum ride comfort. The through deep potholes, do not cause the suspension is progressive, which means that the suspension to block.
Page 49: Braking System
Description 3.3.8 Braking system A pedelec's brake system is primarily operated 3.3.8.2 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 50: Disc Brake
Description 3.3.8.3 Disc brake Figure 36: 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.
Page 51: Mechanical Drive System
Description 3.3.9 Mechanical drive system The pedelec is driven by muscle power, just like a 3.3.9.1 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 52: Electric Drive System
3.3.10.2 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.
Page 53: Charger
3.3.10.3 Charger 3.3.10.5 Integrated battery The following battery can be built into the pedelec: Each pedelec is supplied with a charger. The following BOSCH charger may be used: • the 4 A Charger BPC3400. Observe the operating instructions in the Section 11.4 Documents.
Page 54: On-Board Computer
It controls the system and all messages on the display screen using seven buttons. Figure 43: BOSCH LED Remote control panel The eBike Flow app can be accessed via Bluetooth®. The control panel has an internal lithium ion battery.
Page 55: Description Of Controls And Screens
Description Description of controls and screens 3.4.1 Handlebars Figure 44: Detailed view of handlebars with BOSCH Kiox300, example 1, 6 Handle LED Remote control panel Rear wheel hand brake (behind handlebars) Air valve cap Bell Sag setting wheel Kiox300 display...
Page 56: Control Panel
3.4.2 Control panel The control panel on the handlebars is the on-board computer. It controls the system and all indicators on the display screen using six buttons. Figure 45: Overview of BOSCH LED Remote control panel Symbol Designation Symbol Designation >...
Page 57: System Message
Description 1. Selected level of assistance indicator 3. Battery level indicator (control panel) The higher the selected level of assistance, the The battery level indicator (control panel) shows more the drive system assists with pedalling. the battery charge level. You can also see the battery charge level on the LEDs on the battery eMTB mode is available for Performance Line CX itself.
Page 58: Creating A User Account
The lock function does not provide anti-theft Bosch eBike Flow smartphone app as soon as the protection; it is more a supplement to a app is connected to the on-board computer.
Page 59: Battery Level Indicator (Battery)
Description 3.4.3 Battery level indicator (battery) Each battery has its own level indicator: Figure 46: Position of battery level indicator (1) The five green LEDs on the battery level indicator battery show the charge level when the battery is switched on. Each LED represents about 20% battery capacity.
Page 60: 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 47: SHIMANOSW-E7000 gear shift Up button (gear shift) Down button (gear shift) MY22Z0a - 12_1.0_25.07.2022...
Page 61: Shimano Gear Shift
Description 3.4.5 SHIMANO gear shift There is either a switch control panel or a shifter 3.4.5.3 MTB switch control panel on the right side of the handlebars. There can be three different switches, depending on the model: • 3-switch control panel •...
Page 62: Shifter Sl-M8100
Description 3.4.5.6 Shifter SL-M8100 Figure 52: Shifter SL-M8100 Shifter Attachment screw for shifter MY22Z0a - 12_1.0_25.07.2022...
Page 63: Fork Lock
Description 3.4.6 Fork lock Only applies to vehicles with this equipment The suspension in suspension forks is adjusted 3.4.6.1 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.
Page 64: Handbrake
Description 3.4.7 Handbrake There is a handbrake on the left and right of the handlebars. Figure 53: 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.
Page 65: Technical Data
Highest effective value of < 0.5 m/s² weighted acceleration for the entire body Table 20: Technical data for BOSCH LED Remote on- board computer, BRC3600 Table 17: Emissions from the pedelec* *Not included in the standard scope of delivery 3.5.3 Bicycle lighting 3.5.6...
Page 66: Bosch Powertube 750 Battery
750 Wh Weight 4.4 kg Protection class IP54 Operating temperature -5… +40 °C Storage temperature +10… +40 °C Permitted charging temperature 0… 40 °C range Table 22: Technical data for BOSCH PowerTube 750, BBP3770 horizontal, BBP3771 vertical MY22Z0a - 12_1.0_25.07.2022...
Page 67: Saddle Width
Description 3.5.8 Saddle width 3.5.8.1 BROOKS ENGLAND 3.5.8.3 SELLE ROYAL Riding position Riding position Narrow saddle Position on trekking bike Athletic Position on trekking bike Sharply inclined upper body, Sharply inclined upper body, back at an angle of 30°…60°. back at an angle of 30°…60°. Medium-width saddle Position on city bike Moderate...
Page 68: Puncture Protection Level
Description 3.5.9 Puncture protection level V-GUARD The V-Guard puncture protection 3.5.9.1 SCHWALBE belt comprises of lightweight, cut- resistant fibres. Its webbing ensures highly effective puncture resistance Inserts Webbing for lightweight race and tour tyres. Rubber insert insert Combination SmartGuard® DualGuard Tubeless Easy Double Defense®...
Page 69: Torque
Description 3.5.10 Torque Model Torque Screw 3.5.10.1 SHIMANO quick release version FH-M3050, FH-M4050, FH-MT200-B, FH-MT400, FH-MT400-B, FH-MT500, FH-MT500-B, FH-MT510, FH-MT510-B, FH-RM33, FH-RM35, FH-TX505, FH-TY505, FH-UR600 HB-M3050, HB-M4050, HB-MT200, HB-MT400,HB-MT400-B, HB-RM33 HB-TX505 FH-M7000, FH-M7010, FH-M7010-B HB-M7000, HB-M7010, HB-M7010-B DEORE FH-M618, FH-M618-B, FH-M6000, FH-M6010, FH-M6010-B, HB-M618, HB-M618-B, HB-M6000, HB-M6010, HB-M6010-B...
Page 70 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 3.5.10.3 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...
Page 71 Description 3.5.10.7 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 3.5.10.8 Stem FSA, carbon quill stem, 9 Nm 15 mm spanner 3.5.10.9...
Page 72 Description 3.5.10.13 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...
Page 73 Description 3.5.10.19 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 3.5.10.20 Chainring …...
Page 74 Initial fitting: 3 ± 0.5 Nm Torx® TX 20, 4 × 8 mm Retrofit: 2 ± 0.5 Nm 3.5.10.26 Chain guard Chain guard for BOSCH Motor BDU37xx Max.10 Nm M6 × 10; head: max. 5 mm; length: max. 8.5 mm Attachment screws MY22Z0a - 12_1.0_25.07.2022...
Page 75 Description 3.5.10.27 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 MY22Z0a - 12_1.0_25.07.2022...
Page 76: Transporting And Storing
About these operating instructions Transporting and storing Weight and dimensions for transportation Weight and dimensions during transportation 41 cm 44 cm 22-15-1062 48 cm 54 cm 60 cm 41 cm 41 cm 44 cm 44 cm 22-15-1064 22-15-0064 48 cm 48 cm 54 cm 54 cm...
Page 77 About these operating instructions 41 cm 44 cm 44 cm 22-18-3017 48 cm 22-18-0018 48 cm 51 cm 54 cm 44 cm 44 cm 48 cm 22-18-3018 48 cm 51 cm 22-18-0019 54 cm 56 cm 60 cm 44 cm 41 cm 22-18-3019 48 cm...
Page 78: Designated Handles, Lifting Points
About these operating instructions 41 cm 44 cm 22-18-5026 48 cm 54 cm 41 cm 44 cm 22-18-5033 48 cm 54 cm 41 cm 44 cm 22-18-5034 48 cm 54 cm 44 cm 48 cm 22-18-5035 54 cm 60 cm Table 26: Type number, model and pedelec type * Vehicle weight without battery # Not yet available when the instructions were produced...
Page 79: Transporting
Transportation and storage Transporting 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.
Page 80: Storing
Transportation and storage Storing  Always store pedelec, battery, on-board 4.4.3 Rechargeable battery computer, display and charger separately.  Storage at about 10 °C to 20 °C is beneficial to a long battery life. Storage temperature +10… +40 °C Humidity 30%…85% ...
Page 81: Break In Operation
Transportation and storage 4.4.4 Break in operation New battery  Inspect battery for damage after delivery. Notice  If the batteries are damaged, observe Section 2.1 Handling a damaged or faulty The battery discharges when not in use. This can battery during storage and disposal.
Page 82: Preparing A Break In Operation
Transportation and storage 4.4.4.1 Preparing a break in operation  Remove the rechargeable battery from the pedelec.  Charge battery between 30% and 60% so that 2 or 3 LEDs light up on the battery level indicator.  The pedelec needs to be cleaned with a damp cloth and preserved with wax spray.
Page 83: 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 84: 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 85: Securing The Powertube Bs3 Battery Mount
5.3.1.1 Securing the PowerTube BS3 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.
Page 86 8 Undo rear wheel and push forwards.  The belt or the chain is loosened. Figure 63: 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.
Page 87 27 Turn battery mount over and place on the aluminium brace in the frame. The BOSCH PowerTube BS3 battery mount must be secured by clamping a clip on its rear. 28 Use a TORX® T25 wrench to fasten the screws into the battery mount.
Page 88 Assembly Fitting the motor Position Connection Colour Voltage 29 Insert the motor. Headlight blue 12 V 30 Have second person hold motor. Speed sensor Grey At least 3.3 V 31 Fasten motor screws with Torx Plus® IP40 Rechargeable Black 36 V and torque of 20 ±...
Page 89 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 3.5.10.20...
Page 90: Preparing The Wheel
Assembly 5.3.2 Preparing the wheel There is an arrow on the sides of the tyres with the inscription ROTATION to show the direction of rotation. The inscription says DRIVE on older tyres. The rotation direction arrow indicates the recommended direction of rotation. On road tyres, the direction of rotation is mainly for optical reasons.
Page 91: 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 4 Insert the securing screw on the non-drive equipment side. ...
Page 92: Mm Cross Axle
Assembly 5.3.3.2 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.
Page 93 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 89: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 94: 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 95: Fitting The Pedals
Assembly 5.3.4 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.
Page 96: 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 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...
Page 97: Checking The Stem And Handlebars
Assembly 5.3.6 Checking the stem and handlebars 5.3.6.1 Checking the connections 5.3.6.3 Checking the 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.
Page 98: Operation
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.
Page 99 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 100: Tips For A Greater Range
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.
Page 101: Error Message
Operation Error message 6.3.1 On-board computer The control panel indicates whether a critical or 6.3.2 Rechargeable battery less critical error has arisen in the drive system. The battery is protected against deep discharge, The error messages generated by the drive overcharging, overheating and short circuits by system can be read in the eBike Flow app and by Electronic Cell Protection (ECP).
Page 102: 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 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...
Page 103: Pedelec Adjustment Procedure
Operation 6.5.2 Pedelec adjustment procedure  Observe the correct order for adjustment. For pedelecs with components only Sequence Adjustment Section Saddle • Straighten saddle 6.5.4.1 • Adjust saddle height 6.5.4.3 • Adjust saddle position 6.5.4.5 • Adjust saddle tilt 6.5.4.6 Handlebars 6.5.5 Stem...
Page 104: Saddle
Operation 6.5.3 Saddle 6.5.3.2 Determining saddle shape CAUTION Ladies’ saddle The distance between the ischial tuberosities and Sitting discomfort due to wrong saddle the pubic symphysis is on average a quarter less Around 50% of all pedelec riders experience in women than in men. This is why painful discomfort due to incorrect sitting.
Page 105 Operation To distribute the pressure optimally over the operation or inflammation, it is advisable to avoid female bone structure in the seat area, a ladies’ any pressure in the perineal area and take a saddle should: longer break from pedelec riding after consulting your doctor.
Page 106: Determining Minimum Saddle Width With Corrugated Cardboard
Operation 6.5.3.3 Determining minimum saddle width with corrugated cardboard 6.5.3.4 Determining minimum saddle width with gel cushion 1 Place corrugated cardboard on a flat, hard, 1 Smooth gel cushion. unpadded seat. 2 Place gel cushion on a flat, hard, unpadded 2 Sit in the middle of the corrugated board.
Page 107: Calculating The Saddle Width
Operation 6.5.3.5 Calculating the saddle width 6.5.3.8 Straighten saddle Depending on the position, the following value is  Position saddle in direction of travel. In doing added to the minimum saddle width. so, align the tip of the saddle with the top tube. Position on roadster + 4 cm Position on city bike...
Page 108: Adjusting The Saddle Height
Operation 6.5.3.10 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). •...
Page 109: Setting The Saddle Height With The Remote Control
Operation 6.5.3.11 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.
Page 110: Riding Position
Operation 6.5.4 Riding position The starting point for a comfortable posture is the The pelvis is positioned incorrectly if it tilts slightly correct position of the pelvis. If the pelvis is in the backwards. As a result, the spine becomes curved wrong position, it can cause different types of and can no longer deflect to an optimal extent.
Page 111 Operation Position on roadster Position on city bike Position on trekking Position on sports bike bike Upright, almost vertical Slightly inclined upper Sharply inclined upper Greatly inclined upper posture, body, body, body, back at an angle back at an angle of back at an angle of Back at an angle of Angle of upper body...
Page 112: Straighten Saddle
Operation 6.5.4.1 Straighten saddle 6.5.4.2 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.
Page 113: Adjusting The Saddle Height
Operation 6.5.4.3 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). •...
Page 114: Setting The Saddle Height With The Remote Control
Operation 6.5.4.4 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.
Page 115: Adjusting The Saddle Position
Operation 6.5.4.5 Adjusting the saddle position 6.5.4.6 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.
Page 116: Handlebars
Operation 6.5.5 Handlebars 6.5.5.1 Replace handlebars 6.5.5.3 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 §...
Page 117: Adjusting The Handlebars
Operation 6.5.5.4 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 6.6.2.1), determine the angle of the upper body and upper arm. 2 Pre-tension the back muscles when adjusting the handlebars.
Page 118: Stem
Operation 6.5.6 Stem 6.5.6.1 Replacing the handlebars 6.5.6.3 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 ...
Page 119: Setting The Quill Stem
Operation 6.5.6.5 Setting the quill stem 6.5.6.6 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 120: Adjusting The Angle-Adjustable Stem
Operation 6.5.6.7 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 129: 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 121: Handles
Operation 6.5.7 Handles 6.5.7.1 Replacing the handles 6.5.7.2 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.
Page 122: Tyres
About these operating instructions 6.5.8 Tyres 6.5.8.1 Adjust tyre pressure Tyre pressure in bar for body weight It is not possible to offer a general recommended Tyre width about about about tyre pressure for a particular pedelec or tyre. The 60 kg 80 kg 110 kg...
Page 123: Brake
Operation 6.5.9 Brake The handbrake grip distance can be adjusted to 6.5.9.2 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.
Page 124: Determining The Grip Distance
Operation 2 Set the brake lever angle as indicated in the 6.5.9.3 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°...
Page 125: Replacing Brakes
Operation 6.5.9.4 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. 6.5.9.5 Retracting the brake linings Disc brakes require wearing-in time.
Page 126: Grip Distance On A Shimano St-Ef41 Brake Lever
Operation 6.5.9.6 Grip distance on a SHIMANO ST-EF41 brake lever Only applies to pedelecs with this equipment  Turn setting screw anti-clockwise towards The brake lever position can be adjusted to the rider's requirements. Such adjustment does not minus (–). affect the pressure point or the position of the ...
Page 127: Grip Distance On A Shimano St-Ef41 Handbrake
Operation 6.5.9.7 Grip distance on a SHIMANO ST-EF41 handbrake Only applies to pedelecs with handbrakes: BL-M4100 BL-M7100 BL-M8100 BL-MT200 BL-MT201 BL-MT400 BL-MT401 BL-MT402 BL-T6000 GRX ST-RX600 M7100 M8100 RS785 The handbrake position can be adjusted to the pedelec riders’ requirements. ...
Page 128: Tyres
Operation 6.5.10 Tyres 6.5.10.1 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...
Page 129: Replacing Tyres
Operation 6.5.10.2 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.
Page 130: Gear Shift
Operation 6.5.11 Gear shift Adjust the position of the gear shift to the pedelec 6.5.11.1 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 §...
Page 131: Suspension
Operation 6.5.12 Suspension A pedelec’s fork suspension and rear frame  Follow the correct order for adjustment. damper suspension can be adjusted to the rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Sequence Adjustment Section...
Page 132: Adjusting The Sr Suntour Fork Steel Suspension
Operation 6.5.13.1 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 142: Sag setting wheel (1) on the suspension fork crown ...
Page 133: Adjusting The Sr Suntour Fork Air Suspension
Operation 6.5.13.2 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.
Page 134: Rockshox Paragon Silver Coil Spring
Operation 6.5.13.3 ROCKSHOX Paragon Silver coil spring Only applies to pedelecs with this equipment 1 Put on normal cycling clothing. 7 Check the sag. 2 Ask someone to hold the pedelec. Setting 3 Stand on the pedals. Allow the damper to Prohibited >30% deflect three times.
Page 135 Operation 9 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 147: Screwing and unscrewing the preload adjustment ring ...
Page 136: Adjusting The Rockshox Coil Spring With An External Preload Adjuster
Operation 6.5.13.4 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 clockwise until it locks into position O-ring.
Page 137: Adjusting The Rockshox Fork Coil Spring With Spacer For Pre-Tensioning
Operation 6.5.13.5 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 138 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 156: 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 139: Adjust The Rear Frame Damper Sag
Operation 6.5.14 Adjust the rear frame damper sag Adjustments on the chassis change ride performance significantly. The rider needs to get used to the pedelec and break it in to prevent accidents. Greater sag (20… 30%) A greater sag increases sensitivity to bumps, thus producing greater suspension motion.
Page 140: Adjusting The Suntour Rear Frame Damper
Operation 6.5.14.1 Adjusting the Suntour rear frame damper Only applies to pedelecs with this equipment Every rear frame damper has a specific delivery After setting up the rear wheel damper, check the air pressure ex works. These levels are starting sag to ensure the recommended sag settings are points.
Page 141: Adjusting The Rockshox Rear Frame Damper
Operation 6.5.14.2 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 142 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 143: Fork Rebound Damping
Operation 6.5.15 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.
Page 144: Adjusting The Sr Suntour Fork Rebound Damping
Operation 6.5.15.1 Adjusting the SR SUNTOUR fork rebound damping Only applies to pedelecs with this equipment Figure 160: 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.
Page 145: Adjusting The Rockshox Suspension Fork
Operation 6.5.15.2 Adjusting the RockShox suspension fork Only applies to pedelecs with this equipment Figure 161: Adjusting the RockShox rebound  The fork sag is adjusted.  Turn the rebound screw clockwise towards the tortoise symbol.  The rebound speed is decreased (slower return).
Page 146: Adjusting The Rear Frame Damper Rebound Damper
Operation 6.5.16 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 147: Adjusting The Rockshox Rear Frame Damper
Operation 6.5.16.1 Adjusting the RockShox rear frame damper Only applies to pedelecs with this equipment Figure 163: Position and shape of the rebound adjuster (red) depends on the model  The sag in the rear frame damper is adjusted.  Turn rebound adjuster in the clockwise direction.
Page 148: Compression Adjuster On Rear Frame Damper
Operation 6.5.17 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 149: Adjusting The Suntour Compression Adjuster
Operation 6.5.17.1 Adjusting the Suntour compression adjuster Only applies to pedelecs with this equipment Figure 165: Suntour compression adjuster (1) on the rear frame damper 1 Set the compression adjuster to the middle position. 2 Ride the pedelec over a small obstacle. ...
Page 150: Adjusting The Rockshox Compression Adjuster
Operation 6.5.17.2 Adjusting the RockShox compression adjuster Only applies to pedelecs with this equipment Figure 166: 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 151: Adjusting The Rockshox Threshold
Operation 6.5.17.3 Adjusting the RockShox threshold Only applies to pedelecs with this equipment Figure 167: The lever’s open position (1) and threshold position (2)  Place threshold lever in the threshold position (2).  The threshold function is switched on. ...
Page 152: Riding Light
Operation 6.5.18 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.
Page 153: Adjusting The Headlight
Operation 6.5.18.1 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.
Page 154: On-Board Computer
6.5.19.3 Update software user account first. Software updates are managed by the Bosch Registering on a PC eBike Flow smartphone app. 1 Create the user account on the BOSCH  The on-board computer is now connected to the website. smartphone.
Page 155 About these operating instructions If the key is not immediately verified on the smartphone, the battery level indicator and the display of selected support level on the pedelec flash white to indicate a search for the key. If the key is found, the battery level indicator flashes white.
Page 156: Accessories
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.
Page 157: Trailer
Operation 6.6.2 Trailer 6.6.2.1 Approval for trailer with Enviolo hub Only applies to pedelecs with this equipment CAUTION Only compatible bicycle trailers are approved for ENVIOLO hub gears. Crash caused by brake failure KETTLER The braking distance may be longer if the trailer is carrying excessive load.
Page 158: Approval For Trailer With Rohloff Hub
Operation 6.6.3 Mobile holder 6.6.2.2 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/ ...
Page 159: Pannier Rack
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.
Page 160: 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 pedelec safely on public roads. 8 The clear sounding bell must be fitted and must work.
Page 161: 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 162: Raising The Kickstand
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.
Page 163: Using The Handlebars
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.
Page 164: Using The Battery
Operation 6.16 Using the battery  Switch off the battery and the drive system before 6.16.1.1 Inserting the battery removing or inserting the battery.  The key is inserted in the lock.  The lock is unlocked. 6.16.1 Removing the battery Figure 182: Inserting the integrated battery Figure 181: Removing the integrated battery 1 Place the battery into the lower mount with the...
Page 165: Charging The Battery
Operation 6.16.2 Charging the battery The battery can remain on the pedelec or can be removed for charging. Interrupting the charging process does not damage the battery. The battery is fitted with a temperature monitoring system which only allows charging within a temperature range between 0 °C and 40 °C.
Page 166: Using Pedelec With The Electric Drive System
 Press the On-Off button (battery).  The battery level indicator (control panel) and the indicator for the selected level of assistance go out.  The pedelec is switched off. Figure 183: Position of the On-Off button on the BOSCH LED Remote MY22Z0a - 12_1.0_25.07.2022...
Page 167: Using The On-Board Computer
 Keep the diagnosis port flap closed at all times to ensure no dust or moisture can penetrate through the port. Figure 184: Overview of BOSCH LED Remote control panel 6.18.2 Charging the control panel battery Symbol...
Page 168: Using The Riding Light
About these operating instructions 6.18.3 Using the riding light 6.18.5 Using the push assist system  The drive system needs to be already switched on to turn on the riding light. CAUTION Injury from pedals or wheels The pedals and the drive wheel turn when the push assist system is used.
Page 169: Selecting The Level Of Assistance
About these operating instructions 6.18.6 Selecting the level of assistance 1 Press Push assist button for longer than 1 seconds. Hold down the button. The control panel is used to set how much the  The battery level indicator goes out and a white electric drive should assist the rider when running light in the direction of travel indicates pedalling.
Page 170: Brake
Operation 6.19 Brake 6.19.1 Using the brake lever WARNING Crash caused by brake failure Oil or lubricant on the brake disc in a disc brake or on the rim of a rim brake can cause the brake to fail completely. This may cause a crash with serious injuries.
Page 171: Gear Shift
Operation 6.20 Gear shift The selection of the appropriate gear is a prerequisite for a physically comfortable ride and making sure that the electric drive system functions properly. The ideal pedalling frequency is between 70 and 80 revolutions per minute. ...
Page 172: Use Suspension And Damping
Operation 6.21 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...
Page 173: Adjusting The Sr Suntour Compression Adjuster
Operation 6.21.1 Adjusting the SR SUNTOUR compression adjuster Figure 193: 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.
Page 174: Adjusting The Rockshox Compression Adjuster
Operation 6.21.1.1 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 194: Changing compression adjuster to a harder setting ...
Page 175: Parking The Pedelec
Operation 6.22 Parking the pedelec 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 176: 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 quickly adjustable stem to save 3 Turn handlebars 90° in a clockwise direction. space when parking. 1 Open stem clamping lever. Figure 196: Example of All Up with open stem clamping lever Figure 198: Example of All Up screwed in 2 Pull handlebars into highest possible position.
Page 177: Activating The Lock Function
About these operating instructions 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 178: Cleaning, Servicing And Inspection
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...
Page 179 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.
Page 180 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 7.5.15.2. shift ...
Page 181 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.
Page 182: Before Each Ride
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.
Page 183: Checking The Suspension Seat Post
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.
Page 184: After Each Ride
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: ...
Page 185: Basic Cleaning
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...
Page 186: Clean Frame, Fork, Pannier Rack, Guards And Kickstand
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.
Page 187: Cleaning The Saddle
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.
Page 188: Clean Brake
Cleaning, servicing and inspection 7.3.15 Clean brake 7.3.18 Cleaning the chain 7.3.15.1 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 ...
Page 189: Servicing
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 199: Diagram showing wear, operating hours (x) ...
Page 190: Pannier Rack
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...
Page 191 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.
Page 192 Cleaning, servicing and inspection 7.4.14 Gear shift 7.4.16 Caring for the chain 7.4.14.1 Rear derailleur articulated shafts and jockey wheels  Place newspaper or paper towels underneath to collect chain oil. 1 Lift rear wheel.  Treat front and rear derailleur articulated 2 Turn the crank briskly in an anti-clockwise shafts and jockey wheels with Teflon spray.
Page 193 Cleaning, servicing and inspection 7.4.18 Caring for the brake 7.4.16.1 Caring for the chain and all-round chain guard 7.4.18.1 Caring for 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 ...
Page 194 Cleaning, servicing and inspection Inspection The following tools are required for an inspection: 7.5.1.1 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.
Page 195 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.
Page 196 Cleaning, servicing and inspection 7.5.1.2 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.
Page 197 Cleaning, servicing and inspection 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 ...
Page 198 Cleaning, servicing and inspection 7.5.2 Checking the brake system 7.5.2.2 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 ...
Page 199 Cleaning, servicing and inspection 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 wiggle it gently to than 2.5 mm between the brake lining and...
Page 200 Cleaning, servicing and inspection 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 201 Cleaning, servicing and inspection 7.5.2.6 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.
Page 202 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. ...
Page 203 Cleaning, servicing and inspection 7.5.5.2 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 213: Gauge is inserted Figure 208: Example of a KMC gauge 2 Lower gauge down to the left-hand side.
Page 204 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 217: Indications of wear on a belt Figure 219: Worn tooth profile 1 Carbon tensile fibres are exposed 2 Worn webbing with visible polymer...
Page 205 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.
Page 206 Cleaning, servicing and inspection 3 Press the check gauge down with just one 7.5.9.3 ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 223: Pressing the check gauge down with one finger Figure 225: Attached measuring stick 4 Take reading where line A meets line B.
Page 207 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.
Page 208 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.
Page 209 Cleaning, servicing and inspection 7.5.15 Check gear shift 7.5.14.2 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.
Page 210 Cleaning, servicing and inspection 7.5.15.3 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.
Page 211 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.
Page 212 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.
Page 213 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 ...
Page 214 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 ...
Page 215 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.
Page 216 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...
Page 217 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;...
Page 218 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 7.5.1.3 … O.K. Defective rim New rim as speci- Rims fied in the parts list Once a month Wear on brake Section...
Page 219 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, …...
Page 220 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-...
Page 221 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...
Page 222 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 …...
Page 223 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.
Page 224 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.
Page 225 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.
Page 226 Inspection and maintenance 8.5.8 Inspecting the fork 8.5.8.1 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...
Page 227 Inspection and maintenance 8.5.9 Inspecting the seat post 8.5.9.1 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.
Page 228 Inspection and maintenance 8.5.9.2 Inspecting and greasing BY.SCHULZ 8.5.9.3 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.
Page 229 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.
Page 230 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 •...
Page 231 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.
Page 232 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).
Page 233 About these operating instructions Troubleshooting, fault clearance and repair Troubleshooting and fault 14 If the drive system does not start after about 6 seconds, press the On-Off button (control clearance panel) for at least 2 seconds. The control panel indicates whether a critical or 15 Contact your specialist dealer if the drive less critical error has arisen in the drive system.
Page 234 About these operating instructions 9.1.2 Errors in assistance function Symptom Cause/possible source Remedy Assistance is not Is the battery charged sufficiently? Check battery is charged. available. Recharge the battery if it is almost flat. Is the system switched on?  Press On-Off button (battery). ...
Page 235 About these operating instructions 9.1.3 Battery errors Symptom Cause/possible source Remedy The battery discharges The battery may be at the end of its  Replace old battery with new one. very quickly. useful life. The battery cannot be Is the charger mains plug firmly Disconnect the charger mains plug and plug it in again.
Page 236 About these operating instructions Symptom Cause/possible source Remedy There is an unusual Remove from the battery immediately. smell. Contact the fire service immediately. Observe all the warnings in Section 2 Safety. Fumes are emitted from Remove from the battery immediately. the battery.
Page 237 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 238 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.
Page 239 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.
Page 240 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.
Page 241 Troubleshooting, fault clearance and repair 9.1.7 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.
Page 242 Troubleshooting, fault clearance and repair 9.1.8 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.
Page 243 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.
Page 244 Troubleshooting, fault clearance and repair 9.1.9 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. ...
Page 245 Troubleshooting, fault clearance and repair 9.1.10 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.
Page 246 Troubleshooting, fault clearance and repair 9.1.11 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.
Page 247 Troubleshooting, fault clearance and repair 9.1.12 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 248 Troubleshooting, fault clearance and repair 9.1.13 SR SUNTOUR suspension fork 9.1.13.1 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 249 Troubleshooting, fault clearance and repair 9.1.13.2 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 250 Troubleshooting, fault clearance and repair 9.1.13.3 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 242: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 243: Changing compression adjuster to a harder setting...
Page 251 Troubleshooting, fault clearance and repair 9.1.13.4 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 252 Troubleshooting, fault clearance and repair 9.1.14 RockShox suspension fork 9.1.14.1 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 253 Troubleshooting, fault clearance and repair 9.1.14.2 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 254 Troubleshooting, fault clearance and repair 9.1.14.3 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 250: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 251: Changing compression adjuster to a harder setting...
Page 255 Troubleshooting, fault clearance and repair 9.1.14.4 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 256 Troubleshooting, fault clearance and repair 9.1.15 Rear frame damper 9.1.15.1 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 257 Troubleshooting, fault clearance and repair 9.1.15.2 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 258 Troubleshooting, fault clearance and repair 9.1.15.3 Suspension too soft on inclines The rear frame damper deflects deeply through up, body weight shifts downwards and the pedelec the deflection range The deflection is quickly used loses some momentum. Figure 258: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 259: SR SUNTOUR compression adjuster (1) on the rear frame damper...
Page 259 Troubleshooting, fault clearance and repair 9.1.15.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.
Page 260 Troubleshooting, fault clearance and repair 9.1.16 RockShox rear frame damper 9.1.16.1 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 261 Troubleshooting, fault clearance and repair 9.1.16.2 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 262 Troubleshooting, fault clearance and repair 9.1.16.3 Suspension too soft on inclines The rear frame damper deflects deeply through to the pedelec rider's weight shifts forward and the the deflection range. Deflection is quickly used up, pedelec loses some momentum. Figure 266: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 267: Position and shape of the compression adjuster (blue) depends on the model ...
Page 263 Troubleshooting, fault clearance and repair 9.1.16.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.
Page 264 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: 9.2.3.1 Removing paint damage on the fork •...
Page 265 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).
Page 266 9.2.7 Replacing pedelec components if lock function is installed 9.2.7.1 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 267 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 268 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.
Page 269 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 270 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.
Page 271 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...
Page 272 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.
Page 273 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...
Page 274 Documents Notes MY22Z0a - 12_1.0_25.07.2022...
Page 275 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+ …...
Page 276 Documents Lock ABUS, Bordo 6015 … Kickstand PLETSCHER, Comp40 Flex … Motor BOSCH, Performance Line CX, BDU3740 250 Watt, 85 Nm Rechargeable battery BOSCH, PowerTube 750, BBP3770 Horizontal, 750 Wh On-board computer BOSCH, LED Remote, BHU3600 … Charger BOSCH, charger, BPC3400 ...not available...
Page 277 Documents 11.3.2 ZE 12+ 22-15-2063, 22-15-2064 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie45 LOR Air 80 … Damper … … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong Handlebar width: 680 mm...
Page 278 Documents Motor BOSCH, Performance Line CX, BDU3740 250 Watt, 85 Nm Rechargeable battery BOSCH, PowerTube 750, BBP3770 Horizontal, 750 Wh On-board computer BOSCH, LED Remote, BHU3600 … Charger BOSCH, charger, BPC3400 ...not available MY22Z0a - 12_1.0_25.07.2022...
Page 279 Documents 11.3.3 ZE FS 12+ 22-15-2065, 22-15-2066 … Aluminium 6061 with fully integrated battery cover and Frame equipped to house dual battery Fork SR SUNTOUR, Mobie45 LOR Air 80 … Damper ROCKSHOX, Deluxe Select+ … Steering headset FSA, Orbit E 1.5 Aheadset, tapered Handlebars BY.SCHULZ, Sport Super Strong...
Page 280 Documents Motor BOSCH, Performance Line CX, BDU3740 250 Watt, 85 Nm Rechargeable battery BOSCH, PowerTube 750, BBP3770 Horizontal, 750 Wh On-board computer BOSCH, LED Remote, BHU3600 … Charger BOSCH, charger, BPC3400 ...not available MY22Z0a - 12_1.0_25.07.2022...
Page 281 Documents 11.4 Charger operating instructions MY22Z0a - 12_1.0_25.07.2022...
Page 282 Documents 4A Charger MY22Z0a - 12_1.0_25.07.2022...
Page 283 Documents MY22Z0a - 12_1.0_25.07.2022...
Page 284 Documents MY22Z0a - 12_1.0_25.07.2022...
Page 285 Documents MY22Z0a - 12_1.0_25.07.2022...
Page 286 Documents MY22Z0a - 12_1.0_25.07.2022...
Page 287 Documents MY22Z0a - 12_1.0_25.07.2022...
Page 288 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.
Page 289 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 290 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.
Page 291 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...
Page 292 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: Type no.
Page 293 Appendix Declaration of conformity for incomplete machine MY22Z0a - 12_1.0_25.07.2022...
Page 294 Appendix MY22Z0a - 12_1.0_25.07.2022...
Page 295 Appendix MY22Z0a - 12_1.0_25.07.2022...
Page 296 Keyword index Keyword index torque, CE marking, Brake disc, Chain guard Air valve, - check, Chain guard, position, - clean - clean, Articulated shaft, - replace, torques - care for position, Chain wheel, Axle, Brake lever, Chain wheels, position, - clean - clean torque, 29, 50...
Page 297 Keyword index torque, ated twist grip, dual-cable Dunlop valve, see conventional Key, valve - check plus, Dust seal, - check electric gear shift, Kickstand, position, - care for, 170, 174 - switch gears, - clean, Guards, eBike Flow, - stability - check 57, 153 - register...
Page 298 Keyword index Negative deflection, - use Nipple holes, - use, Saddle, - check, - change saddle tilt, Nipple well, Q-Loc, - change the seat length, - check, position, Quick release, - check Off-road tyres, - inspect, - clean, On-board computer, position, - determine saddle height, 107, 112, 114...
Page 299 Keyword index - check, Vehicle, - clean, technical data, - inspect, position, Wear, torque, Weight, Suspension fork, - shipping weight, - clean - weight, - inspect, 30, 290 Wheel, - service, - check concentricity Suspension seat post, - check, - care for, 89, 90, 93 - fit - clean,...

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Bosch ZEMO SU-E FS 12 Translation Of Original Operating Instructions

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