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Kettler QUADRANO PRO 12 LTD Translation Of Original Operating Instructions

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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Translation of original operating instructions
for KETTLER pedelecs with
SHIMANO SC-E5003 on-board computer
QUADRANO PRO 12 LTD, QUADRANO LITE 11
KS165-IAKD, KS165-IAKW, KS167-IAKD, KS167-IAKW
MY22 K03 - 12 _1. 0_2 0:0 4:20 21

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  • Page 1 KEEP SAFE TO CONSULT AT A LATER DATE Translation of original operating instructions for KETTLER pedelecs with SHIMANO SC-E5003 on-board computer QUADRANO PRO 12 LTD, QUADRANO LITE 11 KS165-IAKD, KS165-IAKW, KS167-IAKD, KS167-IAKW MY22 K03 - 12 _1. 0_2 0:0 4:20 21...

  • Page 2: Table Of Contents

    Contents Contents About these operating instructions Manufacturer Laws, standards and directives Language For your information 1.4.1 Warnings 1.4.2 Markups Type number and model Frame number Identifying the operating instructions Aim of the operating instructions Safety Residual risks 2.1.1 Risk of fire and explosion 2.1.1.1 Rechargeable battery 2.1.1.2...
  • Page 3 Contents 3.3.2.1 Frame 3.3.2.2 Steering system 3.3.2.3 Steering headset 3.3.2.4 Stem 3.3.2.5 Handlebars 3.3.2.6 Fork 3.3.3 Suspension 3.3.3.1 Rigid fork 3.3.3.2 Suspension fork 3.3.4 Wheel 3.3.4.1 Tyres 3.3.4.2 3.3.4.3 Valve 3.3.4.4 Spoke 3.3.4.5 Spoke nipples 3.3.4.6 3.3.5 Braking system 3.3.5.1 Mechanical brake 3.3.5.2 Hydraulic brake...
  • Page 4 Contents 3.5.6 Charger 3.5.6.1 SHIMANO, EC-E6002 3.5.7 Tightening torques Transporting and storing Weight and dimensions for transportation Designated handles, lifting points Transportation 4.3.1 Using the brake transport securing system 4.3.2 Transporting the pedelec 4.3.3 Shipping a pedelec 4.3.4 Transporting the battery 4.3.5 Shipping the battery Storing...
  • Page 5 Contents 6.5.5.1 Handlebar width 6.5.5.2 Hand position 6.5.5.3 Adjusting the handlebars 6.5.6 Stem 6.5.6.1 Adjusting the handlebar height with quick release 6.5.6.2 Setting the quill stem 6.5.6.3 Adjusting the Ahead stem 6.5.6.4 Adjusting the angle-adjustable stem 6.5.7 Ergonomic handles 6.5.7.1 Checking handlebar stability 6.5.8 Tyres...
  • Page 6 Contents 6.19.1 Using the brake lever 6.20 Suspension and damping 6.20.1 Adjusting the Suntour compression adjuster 6.21 Gear shift 6.21.1 Using the derailleur gears 6.22 Parking 6.22.1 Screwing in the All Up handlebars Cleaning, servicing and maintenance Before each ride 7.1.1 Checking the guards 7.1.2...
  • Page 7 Contents 7.4.3 Pannier rack 7.4.4 Mudguard 7.4.5 Servicing the kickstand 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 Leather saddle 7.4.11 7.4.12 Spoke nipples 7.4.13 7.4.14 Gear shift...
  • Page 8 Replacing the lighting 9.6.3 Setting the front light 9.6.4 Checking tyre clearance Recycling and disposal 10.1 Removal of waste guidelines Documents 11.1 Assembly report 11.2 Maintenance instructions 11.3 Parts list 11.3.1 QUADRANO PRO 12 LTD 11.3.2 QUADRANO LITE 11 MY22K03 - 12_1.0_13.08.2021...
  • Page 9 Contents Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Keyword index MY22K03 - 12_1.0_13.08.2021...
  • Page 10 About these operating instructions Thank you for your trust! Copyright KETTLER pedelecs are premium quality vehicles. © KETTLER Alu-Rad GmbH You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product.

  • Page 11: About These Operating Instructions

    About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and KETTLER Alu-Rad GmbH actions. You will find three warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany WARNING Tel.: +49 6805 6008-0...

  • Page 12: Type Number And Model

    Pedelec Type no. Model owner. The frame number is the most important type identifier for verifying ownership. QUADRANO PRO 12 LTD Mountain KS165-IAKD Diamant bike Identifying the operating QUADRANO PRO 12 LTD,...

  • Page 13: Aim Of The Operating Instructions

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

  • Page 14: Safety

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

  • Page 15: Electric Shock

    Safety 2.1.2 Electric shock 2.1.3.3 Incorrect component The wheels are designed exclusively for use with 2.1.2.1 Damage rim brakes or disc brakes. The wheel may break if Damaged chargers, cables and plug connectors an incorrect brake is used. This will cause a crash increase the risk of electric shock.

  • Page 16: Toxic Substances

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

  • Page 17: Safety Markings And Safety Instructions

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

  • Page 18: Battery Vapours Emitted

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

  • Page 19: Description

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

  • Page 20: Improper Use

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

  • Page 21: Permitted Total Weight (Ptw)

    Description 3.1.2 Permitted total weight (PTW) The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is: • the weight of the fully assembled pedelec • plus the rider • plus baggage. Type no.

  • Page 22: Environmental Requirements

    Overview 3.1.3 Environmental requirements You can be ride the pedelec within a temperature Temperatures under -10 °C and over +60 °C must range between -10 °C and +50 °C. The electric be avoided. drive system is limited in its performance outside You must also keep within the following this temperature range.
  • Page 23 Overview The pedelec is unsuitable for the following areas of use: Child's City and bicycles/ Area of use trekking Mountain bikes Racing bicycle Cargo bike Folding bicycle bicycles for bicycles young adults Never drive off- Never drive off- Never drive off- Never drive off- Never drive off- road or perform...

  • Page 24: Nameplate

    EN 15194 0,25 kW / 25 km/h zGG 180 kg EPAC 25 kg BJ 2021 / MJ 2022 Figure 1: Example KETTLER nameplate More No. Designation Description information The manufacturer uses the CE marking to declare that the pedelec CE marking complies with applicable requirements.

  • Page 25: Components

    Description Components 3.3.1 Overview 18 19 20 Figure 2: Pedelec viewed from the right Front wheel Rear light Fork Rear guard Front guard Kickstand Headlight Rear wheel Handlebars Belt Stem Belt guard Frame Motor (behind motor Seat post guard) Saddle Pedal Pannier rack Frame number...

  • Page 26: Chassis

    Description 3.3.2 Chassis The chassis comprises two components: 3.3.2.6 Fork The stem and handlebars are attached to the top • Frame and • steering system end of the fork steerer. The axle is fastened to the fork ends. The wheel is fastened to the axle. 3.3.2.1 Frame The frame absorbs all forces which act on the pedelec from body weight, pedalling and the...

  • Page 27: Suspension

    Description 3.3.3 Suspension Both forks and suspension forks are fitted in this model series. 3.3.3.1 Rigid fork Rigid forks do not feature suspension. They transfer the used muscle and motor power to the road to optimum effect. Pedelecs with rigid forks consume less energy on steep roads and have a greater range than pedelecs with suspension.
  • Page 28 Description Negative deflection (sag) The negative deflection (sag) is the percentage of optimally adjusted. The wheel stays in contact total deflection that is compressed by body with the ground when passing over bumps (blue weight, including equipment (such as a line).
  • Page 29 Description Rebound damping Only applies to pedelecs with this equipment Rebound damping defines the speed at which the Rebound damping needs to be increased to suspension rebounds after being loaded. achieve an optimal setting if the air pressure or Rebound damping controls the suspension fork spring stiffness are increased.
  • Page 30 Description Steel suspension fork structure Air suspension fork structure The stem and the handlebars are fastened to the Depending on the model, the air suspension fork has either fork steerer. The wheel is fastened to the axle. • an air suspension assembly group (orange) and/ •...

  • Page 31: Wheel

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

  • Page 32: Spoke

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

  • Page 33: Braking System

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

  • Page 34: Disc Brake

    Description 3.3.5.3 Disc brake Figure 19: Brake system with disc brake – example Brake disc Brake calliper with brake linings Handlebars with brake lever Front wheel brake disc Rear wheel brake disc On a pedelec with a disc brake, the brake disc is screwed permanently to the wheel hub.

  • Page 35: Seat Post

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

  • Page 36: Mechanical Drive System

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

  • Page 37: Electric Drive System

    Overview 3.3.8 Electric drive system 3.3.9 Rechargeable battery The pedelec has an electric drive system in The lithium ion battery has an interior electronic addition to a mechanical one. protection circuit, which is specifically designed for the charger and the pedelec. The battery temperature is monitored at all times.

  • Page 38: Riding Light

    Overview 3.3.10 Riding light When the riding light is activated, the headlight and the rear light are switched on together. The light is controlled using the light button on the on-board computer and the light switch on the handlebars. 3.3.11 Charger ...

  • Page 39: Description Of Controls And Screens

    Description Description of controls and screens 3.4.1 Handlebars Figure 28: Detailed view of handlebars with SHIMANO SC-E5003 on-board computer, used as example Rear wheel hand brake Handles Bell Main beam switch Headlight Switch On-board computer Shifter Front wheel hand brake MY22K03 - 12_1.0_13.08.2021...

  • Page 40: On-Board Computer

    Description 3.4.2 On-board computer 3.4.2.1 Journey Data indicator Four different types of journey data can be The pedelec is operated using four buttons on the displayed. on-board computer. Display Function GEAR Current selected gear (only visible with electronic gear shift). RANGE Range for the selected level of assistance.

  • Page 41: Maintenance Indicator

    Description 3.4.2.4 Maintenance indicator Indicates that maintenance is required (see Section 6.3.3). 3.4.2.5 Push assist indicator This symbol is displayed if the pedelec is switched to push assist mode. 3.4.2.6 Level of assistance indicator Indicates the current level of assistance. The greater the level assistance is, the longer the indicator bar is.

  • Page 42: Gear Shift

    Operation 3.4.3 Gear shift There is either a switch control panel or a shifter MTB control panel on the right side of the handlebars. There can be three different control panels, depending on the model: • 3-switch control panel • 2-switch control panel or •...
  • Page 43 Operation SHIMANO shifter SL-M8100 Figure 35: Shifter SL-M8100 Shifter MY22K03 - 12_1.0_13.08.2021...

  • Page 44: Hand Brake

    Description 3.4.4 Hand brake There is a hand brake on the left and right of the handlebars. Figure 36: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example • The left-hand brake controls the front wheel brake.

  • Page 45: Fork Lock

    Description 3.4.5 Fork lock Only applies to vehicles with this equipment The suspension in suspension forks is set using 3.4.5.1 SR Suntour fork locks. The fork locks are either directly on the The following (compression adjusters) may be suspension fork or can be controlled using the featured on the suspension fork: remote control on the handlebars.

  • Page 46: Battery Level Indicator (Battery)

    Overview 3.4.6 Battery level indicator (battery) The pedelec has a Shimano BT-E8036 rechargeable battery: Figure 37: Overview of SHIMANO BT-E8036 battery On-Off button The battery switches itself off for an hour after Battery level indicator LED being fully recharged. The charge level for the activated battery is shown The green LED on the battery level indicator on the on-board computer (see Section 3.4.2.3).

  • Page 47: Technical Data

    Overview Technical data 3.5.1 Pedelec 3.5.5 Rechargeable battery 3.5.5.1 SHIMANO, BT-E8036 Transportation temperature -20…+60 °C Storage temperature -20…+70 °C Nominal voltage 36 V Operation temperature -10…50 °C Nominal capacity 17.5 Ah Charging ambient temperature 0 °…40 °C Energy 630 Wh Power output/system 250 W (0.25 kW) Protection class...

  • Page 48: Tightening Torques

    Description 3.5.7 Tightening torques Model Tightening torque Screw On-board computer SC-E5003 Attachment screw 0.8 Nm 3 mm hex bit Shifter SHIMANO DEORE SL-M4100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE SL-M5100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE SL-M6100 Attachment screw 3 Nm...
  • Page 49 Description eightpins H01 Seat post axle 8 Nm 6 mm hex bit Slipper clutch 18 Nm 3 mm hex bit Valve cover 0.5 Nm 5 mm hex bit Postpin axle 8 Nm 5 mm hex bit Rear clamping screw (saddle) 8 Nm 3 mm hex bit M5 attachment screw for outer sleeve...

  • Page 50: Transporting And Storing

    Transporting and storing Transporting and storing Weight and dimensions for transportation Weight and dimensions during transportation KS165-IAKD KS165-IAKW KS167-IAKD KS167-IAKW Table 24: Type number, model and pedelec type **Vehicle weight without battery # Not yet available when the instructions were produced Designated handles, lifting points The box does not have any handles.

  • Page 51: Transportation

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

  • Page 52: Storing

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

  • Page 53: 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 54: 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 55: 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 56: Installing The Wheel In The Suntour Fork

    Assembly 5.3.3 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.3.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this equipment 4 Insert the securing screw on the non-drive side. ...

  • Page 57: Mm Cross Axle

    Assembly 5.3.3.2 20 mm cross axle Only applies to Suntour forks with this equipment 2 Tighten the cross axle with the red handle. CAUTION Crash caused by loose quick release axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
  • Page 58 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 49: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.

  • Page 59: 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 60: Preparing The Limotec Seat Post

    Assembly 5.3.4 Preparing the LIMOTEC seat post Only applies to pedelecs with this equipment 1 Use the seat height formula to calculate the optimum seat post height for the length of rider's leg: Seat height (SH) = inner leg length (I) × 0.9 2 Lower the seat post further into the seat tube 3 The seat post Bowden cable must be tightened in the frame up to the remote control to the...

  • Page 61: Fitting The Pedals

    Assembly 5.3.5 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.

  • Page 62: Checking The Stem And Handlebars

    Assembly 5.3.6 Checking the stem and handlebars 5.3.6.1 Checking the connections 5.3.6.3 Checking the headset backlash 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.

  • Page 63: Operation

    Operation Operation Risks and hazards WARNING WARNING Injuries and death caused by distraction Injuries and fatalities caused by blind spots A lack of concentration while riding increases the Other road users, trucks, cars and pedestrians risk of an accident. This may cause a crash with often underestimate the speed of pedelecs.
  • Page 64 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 65: Tips For A Greater Range

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

  • Page 66: System Messages

    Operation System messages 6.3.1 On-board computer warnings Figure 58: Example: Warning W000 Code Cause Limitation Remedy W101 No vehicle speed signal was The maximum speed at which  Contact your specialist dealer. (W011) detected by the speed assistance is provided is lower sensor.

  • Page 67: Error Message Screen

    Operation 6.3.2 Error message screen If an error message is shown over the entire display, follow the procedure indicated below to reset the screen. 1 Press the On-Off button (battery). 2 Remove the battery from the mount. 3 Replace the battery. 4 Start the system.

  • Page 68: Maintenance Indicator

    Operation 6.3.3 Maintenance indicator The maintenance symbol is displayed when maintenance is required.  Contact your specialist dealer. Figure 60: Maintenance symbol indicator 6.3.4 Battery error message The battery indicates errors with different LED Symbols: statuses. LED on LED off LED flashing Type Status...

  • Page 69: Instruction And Customer Service

    Operation Instruction and customer service The supplying specialist dealer will provide 6.5.1 Preparing customer service. Contact details can be found on The following tools are required to adjust the the pedelec pass for these operating instructions. pedelec: The specialist dealer will explain all the pedelec functions to the new owner in person, this being when the specialist dealer hands over the pedelec Tape measure...

  • Page 70: Pedelec Adjustment Procedure

    Operation 6.5.2 Pedelec adjustment procedure  Observe the correct order for adjustment. For pedelecs with components only Correct Adjustment Section order Saddle • Straighten saddle 6.5.4.1 6.5.4.3 • Adjust saddle height 6.5.4.5 • Adjust saddle position 6.5.4.6 • Adjust saddle tilt If present Adjust saddle spring 6.5.4.8...

  • Page 71: Determining The Sitting Position

    Operation 6.5.3 Determining the sitting position The starting point for a comfortable posture is the correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g. in the shoulder or back. Figure 61: The pelvis is in the right position (green) or incorrect position (red) The pelvis is in the right position if the spine forms...
  • Page 72 Operation Position on roadster Position on city bike Position on trekking Position on sports bike bike Upright, almost vertical Slightly inclined upper Considerably inclined Sharply inclined upper posture, body, upper body, body, back at an angle of back at an angle of 60°– back at an angle of 30°–...

  • Page 73: Adjusting The Saddle

    Operation 6.5.4 Adjusting the saddle 6.5.4.1 Straightening the saddle 6.5.4.3 Adjusting the saddle height   Position saddle in direction of travel. In doing To adjust the saddle height safely, either: so, align the tip of the saddle with the top tube. •...

  • Page 74: Setting The Saddle Height With The Remote Control

    Operation 5 Open the quick release on the seat post to 6.5.4.4 Setting the saddle height with the remote control change the seat height (1). To do so, push the clamping lever away from the seat post (3). Use the seat height formula to set the saddle height: Seat height (SH) = inner leg length (I) ×...

  • Page 75: Adjusting The Saddle Position

    Operation 6.5.4.5 Adjusting the saddle position 3 Unfasten and adjust the designated screw connections, and clamp them with the The saddle can be shifted on the saddle frame. maximum tightening torque for the saddle The right horizontal position ensures an optimal clamping screws.

  • Page 76: Handlebars

    Operation 6.5.5 Handlebars  Check handlebar width and hand position. The narrower the shoulders are, the greater the bend of the handlebars should be (maximum 28°).  Choose different handlebars if necessary. Contact specialist dealer. Straight handlebars are advisable for sports bikes (e.g.

  • Page 77: Stem

    Operation 6.5.6 Stem 6.5.6.1 Adjusting the handlebar height with Adjusting the quick release clamping force quick release Only applies to pedelecs with this equipment CAUTION 1 Open the stem clamping lever. Crash caused by incorrectly set clamping force Applying excessive clamping force damages the quick release.

  • Page 78: Setting The Quill Stem

    Operation 6.5.6.2 Setting the quill stem 6.5.6.3 Adjusting the Ahead stem Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment In the case of a quill stem, the stem and fork In the case of an Ahead stem, the stem is placed steerer form a permanently interconnected directly on the fork steerer, which protrudes over component, which is clamped in the fork steerer.

  • Page 79: Adjusting The Angle-Adjustable Stem

    Operation 6.5.6.4 Adjusting the angle-adjustable stem Only applies to pedelecs with this equipment Angle-adjustable stems are available in different lengths for quill and Ahead stems. Figure 76: Different versions of angle-adjustable stems Adjusting the stem angle (c) changes both the distance from the upper body to the handlebars (b) and the handlebar height (a).

  • Page 80: Ergonomic Handles

    Operation 6.5.7 Ergonomic handles In the case of ergonomically shaped handles, the palm rests on the anatomically shaped handle. A greater contact surface means that the pressure is more evenly distributed. Nerves and vessels are no longer squeezed in the carpal tunnel. Figure 78: Correct (1) and incorrect (2) position of the handle 1 Undo the handle screw.

  • Page 81: Tyres

    Operation 6.5.8 Tyres It is not possible to offer a general recommended Tyre pressure in bar for body tyre pressure for a particular pedelec or tyre. The weight correct tyre pressure largely depends on the Tyre width about about about weight load on the tyres, mainly determined by 60 kg 80 kg...

  • Page 82: Brake

    Operation 6.5.9 Brake The brake lever grip distance can be adjusted to 6.5.9.2 Brake handle tilt angle ensure that it can be reached more easily. The The nerves that pass through the carpal tunnel pressure point can also be adjusted to the rider's are connected to the thumb and the index and preferences.

  • Page 83: Determining The Grip Distance

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

  • Page 84: Retracting The Brake Linings

    Operation 6.5.9.4 Retracting the brake linings Disc brakes require wearing-in time. The braking force increases over time. The braking force is increased during break-in time. This is also the case when the brake pads or brake discs are replaced. 1 Accelerate pedelec to 25 km/h. 2 Brake pedelec until it comes to a halt.

  • Page 85: Gear Shift

    Operation 6.5.10 Gear shift Adjust the position of the gear shift to the rider’s 2 Place control panel or shifter into the position needs. where the rider can use the control panel or the shifter with their thumb and/or index finger. 1 Undo attachment screw.

  • Page 86: On-Board Computer

    Operation 6.5.11 On-board computer Adjust the position of the on-board computer to 2 Place on-board computer into the position the rider’s needs. where the rider can use the on-board computer with their thumb and/or index finger. 1 Undo attachment screw. 3 Tighten attachment screw.

  • Page 87: Suspension

    Operation 6.5.12 Suspension A pedelec’s fork suspension and rear frame  Follow the the correct order for adjustment. damper suspension can be adjusted to the rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Rear frame Sequence Adjustment...

  • Page 88: Adjusting The Suntour Fork Steel Suspension

    Operation 6.5.13.1 Adjusting the Suntour fork steel suspension Only applies to pedelecs with this equipment 1 You will find the sag setting wheel (1) beneath the plastic cover on the crown. Remove the plastic cover. Figure 87: Sag setting wheel (1) on the suspension fork crown ...

  • Page 89: Adjusting The Suntour Fork Air Suspension

    Operation 6.5.13.2 Adjusting the Suntour fork air suspension Only applies to pedelecs with this equipment  The air valve is located beneath the air valve 1 Attach a high-pressure damper pump to the air cap on the crown. Twist off the air valve cap. valve.

  • Page 90: Fork Rebound Damping

    Operation 6.5.14 Fork rebound damping Only applies to pedelecs with this equipment Rebound damping in the suspension fork and the Rebound damping needs to be increased to rear frame damper determines the speed at which achieve an optimal setting if the air pressure or the rear frame damper rebounds after being spring stiffness are increased.

  • Page 91: Adjusting The Suntour Fork Rebound Damping

    Operation 6.5.14.1 Adjusting the Suntour fork rebound damping Only applies to pedelecs with this equipment Figure 90: Example of Suntour rebound screw (1)  The fork sag is adjusted. 1 Turn the rebound screw in a clockwise direction to the closed position until it stops. 2 Turn the rebound screw slightly in an anti- clockwise direction.

  • Page 92: Lighting

    Operation 6.5.15 Lighting Example 1 If the front light is positioned too high, oncoming traffic will be dazzled. This can cause a serious accident with fatalities. Example 2 Positioning the front light correctly can ensure that oncoming traffic is not dazzled and no-one is put at risk. Example 3 If the front light is positioned too low, the space ahead is not illuminated to an optimum extent and the rider's vision is reduced in the dark.
  • Page 93 Operation 4 Place pedelec 5 m from the wall. 6 Switch on riding light. 5 Stand the pedelec up straight. Hold the handlebars straight with both hands. Do not use the kickstand. Figure 93: Light positioned too high (1), correctly (2) and too low (3) 7 Check the position of the light beam.

  • Page 94: Accessories

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

  • Page 95: Trailer

    Crash caused by brake failure KETTLER The braking distance may be longer if the trailer is carrying excessive load. The long braking KETTLER QUADRIGA child trailer distance can cause a crash or an accident and injuries. BURLY  Never exceed the specified trailer load.

  • Page 96: Mobile Holder

    Operation 6.6.3 Mobile holder Only applies to pedelecs with this equipment A holder for SP Connect mobile case is fitted to the stem.  Observe the operating instructions for the mobile and the SP Connect mobile case.  Use on tarmacked roads only. ...

  • Page 97: Personal Protective Equipment And Accessories For Road Safety

    Operation Personal protective equipment and accessories for road safety Seeing and being seen is crucial in road traffic. 7 The two separate brakes on the pedelec must The following requirements must be met for riding work at all times. a road-safe vehicle on public roads. 8 The clear sounding bell must be fitted and must work.

  • Page 98: Raising The Kickstand

    Operation Raising the kickstand  Distribute the baggage as evenly as possible between the left- and right-hand side.  Use your foot to raise the kickstand completely  We recommend the use of panniers and before setting off. baggage baskets. 6.10 Using the pannier rack CAUTION...

  • Page 99: Using The Pedals

    Operation 6.12 Using the pedals  The ball of the foot is placed on the pedal when riding and pedalling. Figure 97: Correct (1) and incorrect (2) foot position on the pedal 6.13 Using the multifunctional handlebars or bar ends ...

  • Page 100: Rechargeable Battery

    Operation 6.16 Rechargeable battery  Switch off the battery and the drive system before removing or inserting the battery. 6.16.1 Removing the BT-E8036 battery 1 Open the key hole flap. 2 Insert key in the locking cylinder. Figure 100: Battery is unlocked 5 Press on the double latch plate.

  • Page 101: Inserting The Bt-E8036 Battery

    Operation 6.16.2 Inserting the BT-E8036 battery 1 Place battery into the mount with the contacts facing the front. 2 Push battery into the frame. Figure 103: LED light on the charger (1) The LED on the charger has three statuses: Status Meaning Lights up...

  • Page 102: Using Pedelec With The Electric Drive System

    Operation 6.17 Using pedelec with the electric drive system 6.17.1 Switching on the electric drive 6.17.2 Switching off the electric drive system system The system switches off automatically ten minutes CAUTION after the last command. The drive system can also be switched off on the Crash caused by lack of readiness for braking battery.

  • Page 103: Using The On-Board Computer

    Operation 6.18 Using the on-board computer 6.18.1 Using the riding light CAUTION  The electric drive system is switched on.  Press the light button. Crash caused by distraction  The riding light is switched on. A lack of concentration while riding increases the risk of an accident.

  • Page 104: Selecting The Level Of Assistance

    Operation  The push assist system helps with pushing the 6.18.5 Resetting the trip distance (DST) pedelec. The speed can be a maximum of 1 Press the select button repeatedly. 6 km/h in this case.  The trip distance (DST) is displayed. 3 Release down button.

  • Page 105: 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 106: Suspension And Damping

    Operation 6.20 Suspension and damping Compression adjuster set to hard Compression adjuster set to soft • Causes the suspension fork to move higher within • Causes the fork to deflect quickly and easily. This the deflection range. This improves efficiency, makes it easier to maintain speed and maintains momentum and makes it easier to ride momentum when riding over uneven rugged...

  • Page 107: Adjusting The Suntour Compression Adjuster

    Operation 6.20.1 Adjusting the Suntour compression adjuster Figure 110: 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 108: Gear Shift

    Operation 6.21 Gear shift The selection of the appropriate gear is a prerequisite for a physically comfortable ride and making sure that the electric drive system functions properly. The ideal pedalling frequency is between 70 and 80 revolutions per minute. ...

  • Page 109: Parking

    Operation 6.22 Parking 6 Remove the on-board computer (see Notice Section 6.18.1.1), battery (see Section 6.16.1.1, 6.16.2.1 or 6.16.3.1) and mobile phone to Heat or direct sunlight can cause the tyre pressure protect against theft. to increase above the permitted maximum 7 Clean and service pedelec after every ride;...
  • Page 110 Operation 2 Pull handlebars into highest possible position. Figure 113: All Up pulled into highest possible position 3 Turn handlebars 90° in a clockwise direction. Figure 114: All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever. MY22K03 - 12_1.0_13.08.2021...

  • Page 111: Cleaning, Servicing And Maintenance

    Cleaning, servicing and maintenance Cleaning, servicing and maintenance  Clean, service and maintain pedelec as indicated on check list. Complying with these measures is the only way to reduce wear on components, increase the operating hours and guarantee safety. Check list before each ride Check list for weekly tasks Check everything is sufficiently Clean chain...
  • Page 112 Cleaning, servicing and maintenance Check list for monthly tasks Check list for monthly tasks   Cleaning the battery Section 7.3.2 Clean hub Section 7.3.12   Clean control panel Section 7.3.1 Cleaning the frame Section 7.3.4   Clean on-board computer Section 7.3.1 Clean tyres Section 7.3.10...
  • Page 113 Cleaning, servicing and maintenance Check list for tasks to do every six months (or every 1,000 Check list for tasks to do every six months (or every 1,000 Check Bowden cables gear  Check steering headset Section 8.5.6  Section 7.5.10.2 shift ...
  • Page 114 Cleaning, servicing and maintenance CAUTION WARNING Crash and falling caused by unintentional Crash caused by brake failure activation Oil or lubricant on the brake disc in a disc brake There is a risk of injury if the drive system is or on the rim of a rim brake can cause the brake activated unintentionally.

  • Page 115: Before Each Ride

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

  • Page 116: Checking The Bell

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

  • Page 117: After Each Ride

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

  • Page 118: Basic Cleaning

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

  • Page 119: Frame, Fork, Pannier Rack, Guards And Kickstand

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

  • Page 120: Leather Saddle

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

  • Page 121: Brake

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

  • Page 122: Servicing

    Cleaning and servicing Servicing Complying with these servicing instructions is the 7.4.1 Frame only way to reduce wear on components, increase the operating hours and guarantee safety. Notice  Hard wax polish and protection wax are particularly resistant on gloss paintwork. These car accessory retail products are unsuitable for matt paint finishes.

  • Page 123: Pannier Rack

    Cleaning and servicing 7.4.3 Pannier rack 7.4.6 Stem 1 Dry pannier rack with a cloth. 1 Spray painted and polished metal surfaces with wax spray and leave to dry. 2 Spray pannier rack with spray wax and leave to dry. 2 Wipe away any wax residue with a cloth.

  • Page 124: Leather Handle

    Cleaning and servicing 7.4.10 Leather saddle 7.4.8.2 Leather handle Standard leather care products keep leather Standard leather care products keep leather smooth and resistant, brighten its appearance and smooth and resistant, brighten its appearance and improve or replace stain protection. improve or replace stain protection.

  • Page 125: Gear Shift

    Cleaning and servicing 7.4.14 Gear shift links. The faster the crank is turned, the thinner the threads of oil will be. 7.4.14.1 Rear derailleur articulated shafts and jockey wheels  Treat front and rear derailleur articulated shafts and jockey wheels with Teflon spray. 7.4.14.2 Shifter Notice Figure 116: Lubricating the chain...

  • Page 126: Caring For The Brake

    Cleaning and servicing 7.4.17 Caring for the brake 7.4.17.1 Caring for the brake Notice  Never treat brake levers with degreaser or penetrating oil spray.  Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision mechanics oil.

  • Page 127: Maintenance

    Cleaning and servicing Maintenance The following tools are required for maintenance: 7.5.1.1 Checking the tyre pressure Notice Gloves If the tyre pressure is too low in the tyre, the tyre does not achieve its load bearing capacity. The Ring spanners 8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm tyre is not stable and may come off the rim.
  • Page 128 Cleaning and servicing Dunlop valve 6 Screw the rim nut gently against the rim with the tips of your fingers. Only applies to pedelecs with this equipment  Correct tyre pressure if necessary (see The tyre pressure cannot be measured on the Section 6.5.8).
  • Page 129 Cleaning and servicing 7.5.1.2 Checking the tyres The tread is far less important for bicycle tyres 2 Check the side walls for wear. If there are any than it is for car tyres, for example. Consequently, cracks or tears, the tyre must be replaced. tyres can still be used with a worn tread with the exception of tyres on mountain bikes.

  • Page 130: Checking The Rims

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

  • Page 131: Checking The Brake System

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

  • Page 132: Checking The Disc Brake

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

  • Page 133: Checking The Back-Pedal Brake

    Cleaning and servicing 7.5.2.5 Checking the back-pedal brake Only applies to pedelecs with this equipment  There are sharp corners and edges on the back- pedal brake. Wear gloves. 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube. ...

  • Page 134: Checking The Rim Brake

    Cleaning and servicing 7.5.2.6 Checking the rim brake Only applies to pedelecs with this equipment Checking the brake linings Checking the rim braking surface for wear  We recommend that you also replace the rims The side wall is more prone to wear in rim brakes. at the same time as every second brake lining The wear depends on the stress loads during replacement.

  • Page 135: Checking The Lighting

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

  • Page 136: Checking The Stem

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

  • Page 137: Checking The Derailleur Gears

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

  • Page 138: Adjusting Gear Shift

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

  • Page 139: Bowden-Cable-Operated Twist Grip, Dual-Cable

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

  • Page 140: Maintenance

    Maintenance Maintenance Initial inspection Component-specific maintenance tasks After 200 km or 4 weeks after purchase High-quality components require extra maintenance. Maintenance tasks require Vibrations produced while riding can cause technical expertise, special tools and special screws and springs that were tightened during lubricants.
  • Page 141 Maintenance Suspension fork maintenance intervals Maintenance intervals for suspension seat post Suntour suspension fork by.schulz suspension seat post  Maintenance 1 After the first Every 50 hours 250 km; every  Maintenance 1,500 km after  Maintenance 2 Every 100 hours that FOX suspension fork Suntour suspension seat post...
  • Page 142 Maintenance Maintenance intervals for rear frame damper Maintenance intervals for hub RockShox rear frame damper SHIMANO 11-speed hub  Service air chamber assembly 1,000 km after Every 50 hours start of use, then  Internal oil change and maintenance every 2 years or ...

  • Page 143: Carry Out Initial Inspection

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

  • Page 144: Maintenance Instructions

    Maintenance Maintenance instructions Complying with these maintenance instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Diagnosis and documentation of current status Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection...
  • Page 145 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.7 O.K. Dirt Cleaning month Once a Care for Section 7.4.8 … O.K. Untreated Talcum powder month Handles before Wear; check if Section 7.1.11 …...
  • Page 146 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months … Section 7.4.13 O.K. Untreated 6 months Wear Section 7.5.1.3 … O.K. Defective rim New rim as specified Rims in the parts list once a Wear on brake Section 7.5.2.6...
  • Page 147 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.8 O.K. Dirt Cleaning month 6 months Care for … O.K. Untreated Leather wax Seat post 6 months Complete clean, …...
  • Page 148 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Venting … See manufac- O.K. hours turer Cleaning … See manufac- O.K. hours turer Venting … See manufac- O.K. RockShox hours turer suspension seat post Complete mainte- …...
  • Page 149 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Drive/gear shift Chain/ 6 months Check for damage Check for … O.K. Damage Refasten if necessary cassette/ damage or replace as speci- pinion/chain- fied in parts list ring Chain guard/ 6 months...
  • Page 150 Maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Miscellaneous before Stability Section 7.1.5 … O.K. Loose Firm each ride Once a Dirt … Section 7.3.4 O.K. Dirt Cleaning month Pannier rack 6 months Servicing …...

  • Page 151: Servicing The Frame

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

  • Page 152: Maintaining The Stem

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

  • Page 153: Servicing The Steering Headset

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

  • Page 154: Servicing The Carbon Suspension Fork

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

  • Page 155: Servicing Seat Post

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

  • Page 156: By.schulz Suspension Seat Post

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

  • Page 157: Eightpins Ngs2 Seat Post

    Maintenance 8.5.8.4 Eightpins NGS2 seat post Only applies to pedelecs with this equipment Removing the seat post 5 Pull cartridge from the piston rod while pushing the outer sleeve into the frame at the same 1 Use a 2.5 mm hex key to turn the height time to help.
  • Page 158 Maintenance 9 Pull out the outer sleeve end cap from the Caring for the outer sleeve counter support on the Postpin interface on the 1 Detach spring washer or outer sealing ring. seat post. Figure 141: Removed spring washer Figure 139: Pulling the end cap out 2 Carefully remove the wiper from the groove.
  • Page 159 Maintenance 8 Carefully re-insert dry felt ring with one end in Increasing the air pressure the designated groove. 1 Use 3 mm hex spanner to unscrew valve cap. 9 Unfurl felt ring within the outer sleeve, so that it lies on the groove. 10 Carefully press felt ring into the groove by hand.
  • Page 160 Maintenance 5 Use a 3 mm hex spanner to screw the valve lid 3 Set the torque to 18 Nm with a torque wrench back on and tighten with a maximum of 0.5 Nm. and a 6 mm hex bit with a shaft length of at least 25 mm.
  • Page 161 Maintenance installing the outer sleeve and slide bushing Notice 1 Carefully push slide bushing tube into the seat tube.  Never pull Bowden cable forwards at an angle. 2 Press outer sleeve downwards with your hand. 4 Carefully push cartridge into the seat tube. Pull 3 Use a 3 mm hex spanner to fasten the the Bowden cable out of the frame to help.
  • Page 162 Maintenance 9 Carefully insert slide bushing tube into the seat tube. Figure 166: Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper. Figure 163: Inserting the slide bushing tube into the seat tube 10 Place outer sleeve on the seat tube and push downwards firmly.

  • Page 163: Eightpins H01 Seat Post

    Maintenance 8.5.8.5 Eightpins H01 seat post Only applies to pedelecs with this equipment Removing the seat post Removing the outer sleeve and slide bushing 1 Use a 5 mm hex spanner to unscrew the 1 Use a 3 mm hex spanner to remove Postpin axle.
  • Page 164 Maintenance 4 Carefully remove the wiper from the groove. 13 Insert cleaned or new wiper in the upper groove. 14 Stretch spring washer over the wiper. Figure 177: Removing the wiper Figure 181: inserting and fastening the wiper 5 Use a small, sharp object to look for and remove the end of the felt ring.
  • Page 165 Maintenance Clean slide bushing 3 Clean the seat post longitudinal grooves with a damp cloth. 1 Clean the slide bushing tube with a damp cloth. Figure 182: Cleaning the slide bushing tube Figure 185: Cleaning the longitudinal groove Notice 4 Apply grease into the longitudinal groove and on both cross-pieces.
  • Page 166 Maintenance installing the outer sleeve and slide bushing 5 Look at the frame interface through the hole in the Postpin. Push the seat post down until the 1 Carefully push slide bushing tube into the seat Postpin mounting interface on the seat post tube.

  • Page 167: Rear Frame Damper

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

  • Page 168: Fox Component-Specific Maintenance

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

  • Page 169: Troubleshooting, Fault Clearance And Repair

    Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Troubleshooting and fault 9.1.2 Warning messages and LEDs clearance All warning messages and the meaning of the different LEDs are explained in Section 6.2. The components of the drive system are checked constantly and automatically.

  • Page 170: Assistance Function

    Troubleshooting, fault clearance and repair Assistance function Symptom Cause Remedy Check battery charge level. Is the battery charged sufficiently? Recharge the battery if it is almost flat. Does the rider ride up long inclines in Switch off the drive system. summer weather or with a heavy load for a Wait a moment and then check again.
  • Page 171 Troubleshooting, fault clearance and repair Rechargeable battery Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace battery with new one. quickly. service life. All five battery indicators are The drive unit firmware version may not be ...

  • Page 172: Lighting

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

  • Page 173: Miscellaneous

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

  • Page 174: Suntour Suspension Fork

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

  • Page 175: Rebounding Too Slowly

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

  • Page 176: Suspension Too Soft On Inclines

    Troubleshooting, fault clearance and repair 9.5.1.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. The deflection is quickly used up, body weight shifts forward and the pedelec loses some momentum. Figure 198: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 199: Changing compression adjuster to a harder setting...

  • Page 177: Excessively Hard Damping On Bumps

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

  • Page 178: Repair

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

  • Page 179: Recycling And Disposal

    Recycling and disposal Recycling and disposal This device is marked according to the recycling saves reserves of raw materials and European Directive 2012/19/EU on ensures that all the regulations for protection of waste electrical and electronic health and the environment are adhered to when equipment –...
  • Page 180 Recycling and disposal Waste type Disposal Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Biodegradable cleaning cloths daubed in oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer.

  • Page 181: Documents

    Documents 11.1 Assembly report Date: Frame number: Components Description Criteria Measures if rejected Accept- Assembly/inspection Tests Rejection 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 182 Components Description Criteria Measures if rejected All complete, state, Damaged or not all Reflectors O.K. New reflectors fastening complete 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.

  • Page 183: Maintenance Instructions

    11.2 Maintenance instructions Diagnosis and documentation of current status Date: Frame number: Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Kickstand 6 months Check mount fastening Functional check O.K.
  • Page 184 Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptan Rejection Lighting system First examination O.K. Error message Contact battery Rechargeable 6 months manufacturer; take out of battery service, new battery Connections, correct O.K. Cable defective, New cabling Light cabling 6 months wiring no light...
  • Page 185 Technical inspection, checking safety, test ride Components Description Criteria Measures if rejected Assembly/inspection Tests Acceptanc Rejection No full braking; braking Locate defective part in brake Brake system 6 months Functional check O.K. distance too long system and correct Gear shift under Problems when shifting 6 months Functional check...
  • Page 186 Notes MY22K03 - 12_1.0_13.08.2021...

  • Page 187: Parts List

    Documents 11.3 Parts list 11.3.1 QUADRANO PRO 12 LTD KS165-IAKD, KS165-IAKW Frame Fork Rigid, carbon Damper … … Steering headset FSA, No. 55R 1.5 inch Handlebars SATORI, Deviant Bow Handlebar width 680 mm, carbon Handles ERGON, GA3 Winged grips Stem...
  • Page 188 Documents Lock Stand/stand mount URSUS, Wave Motor SHIMANO, EP8 DU-EP800 250 Watt, 85 Nm Rechargeable battery SHIMANO, BT-E8036 630 Wh On-board computer SHIMANO, SC-E5000 Charger SHIMANO, EC-6002 1.8 V ...not available # Not yet available when the instructions were produced MY22K03 - 12_1.0_13.08.2021...
  • Page 189 Tube SCHWALBE, AV19 Front lamp FUXON, FF-100 EB/WB10 100 lx Rear lamp FUXON, R-Glow EB Dynamo … … Pannier rack MONKEYLINK, MonkeyLoad Carrier Guards SKS, Edge AL C66 Chain guard #, Kettler Quadrano Lock Stand URSUS, Wave MY22K03 - 12_1.0_13.08.2021...
  • Page 190 Documents Motor SHIMANO, EP8 DU-EP800 250 Watt, 85 Nm Rechargeable battery SHIMANO, BT-E8036 630 Wh On-board computer SHIMANO, SC-E5000 Charger SHIMANO, EC-6002 1.8 V ...not available # Not yet available when the instructions were produced MY22K03 - 12_1.0_13.08.2021...

  • Page 191: Glossary

    Glossary Glossary Bicycle for young adults Drive belt Source: ISO 4210-2: pedelec designed for use on Source: EN 15194:2017: seamless ring belt which public roads by a young adult whose weight is less is used as a means of transmitting drive force. than 40 kg, with maximum saddle height of Electrical control system 635 mm or more and less than 750 mm (see...
  • Page 192 Glossary Fracture Minimum insertion depth Source: EN 15194:2017: unintentional separation Source: EN 15194:2017: mark indicating the into two or more parts. minimum insertion depth of handlebar stem into fork steerer (fork stem) or seat post into frame. Maintenance Model year Source: DIN 31051: maintenance is generally performed at regular intervals and often carried Source: ZEG: the model year refers to the first...
  • Page 193 Glossary Placing on the market Shut-off speed Source: Directive 2006/42/EC on Machinery, Source: EN 15194:2017: speed reached, by the 17.05.2006, Making available for the first time in pedelec, at the moment the current has dropped the Community machinery or partly completed to zero or to the no load current value.

  • Page 194: Abbreviations

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

  • Page 195: Appendix

    The following other technical standards have been applied: • EN 11243:2016: Cycles – Pannier racks for bicycles – Requirements and test methods Cologne, 19/04/2021 ………………………………………………………………………………………………………………… Egbert Hageböck, Managing Director of KETTLER Alu-Rad GmbH * Community member who is authorised to compile the technical documentation MY22K03 - 12_1.0_13.08.2021...

  • Page 196: Keyword Index

    Keyword index Keyword index – caring for, 124 – caring for, 122 Air valve, 29 - cleaning, 120 - cleaning, 118 Articulated shaft, - maintaining, 127, 136 Handles, - caring for 124 Charger, - cleaning, 118 Axle, 29 - disposing of, 178 Headlight, 36 Chassis, 25 Headset, see steering headset...
  • Page 197 Keyword index Schrader valve, 31 Q-Loc, 29 Weight, Rear derailleur, 35 – Shipping weight, 49 – caring for, 124 – Weight, 49 Rear light, 36 Wheel, 30 Rear wheel brake, 33 - installing, 55, 58 Rebound adjuster, 29 Winter break, see Break in operation Rebound damping 28 Riding light, 37 Rim brake locking lever 32...

This manual is also suitable for:

Quadrano lite 11Ks165-iakdKs165-iakwKs167-iakdKs167-iakw

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