Hercules BOSCH KIOX 300 INTUVIA 100 Translation Of Original Operating Instructions

Hide thumbs Also See for BOSCH KIOX 300 INTUVIA 100:

page of 310

/ 310
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE

Translation of original operating instructions

for HERCULES pedelecs with

BOSCH Purion on-board computer

F U T U R A :

I - 8 , I - 9

LY O N :

F 7 , R 7

N I Z Z A :

F 7 N L

P r i m a :

E 5

R O B F O L D :

F 7 , R 8

2 4 - Q - 0 0 0 4 . . . 2 4 - Q - 0 0 0 9 , 2 4 - Q - 0 0 1 8 , 2 4 - Q - 0 0 1 9 , 2 4 - Q - 0 0 2 3 , 2 4 - Q - 0 , 0 3 6 , 2 4 - Q - 7 8 1 4 , 2 4 - Y- 0 0 0 7 , 2 4 - Y- 0 0 0 8

M Y 2 4 H 0 7 - 1 2 _ 1 . 0 _ 2 9 . 0 1 . 2 0 2 4

Table of Contents

Need help?

Do you have a question about the BOSCH KIOX 300 INTUVIA 100 and is the answer not in the manual?

Questions and answers

Summary of Contents for Hercules BOSCH KIOX 300 INTUVIA 100

Page 1 READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for HERCULES pedelecs with BOSCH Purion on-board computer F U T U R A : I - 8 , I - 9...
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 Contents 3.3.2.6 Fork 3.3.2.7 Steering system 3.3.2.8 Steering headset 3.3.2.9 Stem 3.3.2.10 Handlebars 3.3.2.11 Suspension fork 3.3.2.12 SR SUNTOUR, NEX E25 DS-HLO-700C 3.3.2.13 SR SUNTOUR cartridge HLO 3.3.3 Wheel 3.3.3.1 Tyres 3.3.3.2 Tube-type tyre 3.3.3.3 3.3.3.4 Valve 3.3.3.5 Spoke 3.3.3.6 Spoke nipples 3.3.4 Brake...
Page 4 Contents 3.5.3 Tyres 3.5.3.1 SCHWALBE puncture protection level 3.5.4 Torque Transporting and storing Weight and dimensions for transportation Designated handles, lifting points Transportation 4.3.1 Using the transport securing system 4.3.2 Transporting the pedelec 4.3.2.1 By car 4.3.2.2 By train 4.3.2.3 By local transport 4.3.2.4 By long-distance bus...
Page 5 Contents 6.5.3 Seat post 6.5.3.1 Adjusting the seat post to body weight 6.5.4 Saddle 6.5.4.1 Replacing the saddle 6.5.4.2 Determining the saddle shape 6.5.4.3 Determining the minimum saddle width 6.5.4.4 Selecting the saddle hardness 6.5.4.5 Adjusting the saddle hardness 6.5.4.6 Straightening the saddle 6.5.4.7 Adjusting the saddle height...
Page 6 Contents 6.5.14.1 Adjusting the SR Suntour rebound damper suspension fork 6.5.15 Riding light 6.5.15.1 Replacing the headlight 6.5.15.2 Replacing the rear light and (spoke) reflector 6.5.15.3 Setting the riding light 6.5.15.4 Adjusting the headlight 6.5.16 On-board computer 6.5.16.1 Creating a user account 6.5.16.2 Connecting the on-board computer to a smartphone 6.5.16.3...
Page 7 Contents 6.10.3 Charging the battery 6.11 Straightening the quickly adjustable stem 6.12 Using the pannier rack 6.13 Raising the kickstand 6.14 Using the saddle 6.14.1 Using the leather saddle 6.15 Using the pedals 6.16 Setting the saddle height with the remote control 6.16.1 Lowering the saddle 6.16.2...
Page 8 Contents Cleaning, maintenance 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 Checking the pannier rack 7.1.6 Checking the mudguards 7.1.7 Check wheel concentricity 7.1.8 Checking the quick releases 7.1.9 Checking the suspension seat post...
Page 9 Contents 7.4.8.2 Maintaining the leather handles 7.4.9 Maintaining the seat post 7.4.9.1 Maintaining the suspension seat post 7.4.9.2 Maintaining the carbon seat post 7.4.10 Maintaining the rims 7.4.11 Maintaining the leather saddle 7.4.12 Maintaining the hub 7.4.13 Maintaining the spoke nipples 7.4.14 Maintaining the gear shift 7.4.14.1...
Page 10 Contents 8.5.1 Inspect frame 8.5.1.1 Inspecting the carbon frame 8.5.2 Inspecting the pannier rack 8.5.3 Inspecting and maintaining the rear frame damper 8.5.4 Inspecting the gear hub 8.5.4.1 Adjusting the hub with cone bearing 8.5.5 Inspecting the stem 8.5.6 Inspect and grease steering headset 8.5.7 Inspecting the axle with quick release 8.5.8...
Page 11 Contents 9.3.6 Checking suspension fork-tyre clearance 9.3.7 Replacing pedelec components if lock function is installed 9.3.7.1 Replacing a smartphone 9.3.7.2 Replacing the on-board computer 9.3.7.3 Activating the lock function after motor replacement Recycling and disposal 10.1 Guidelines on removal of waste Documents 11.1 Assembly report...
Page 12 About these operating instructions Thank you for your trust! Copyright HERCULES pedelecs are premium quality © HERCULES GmbH bicycles. You have made an excellent choice. Your specialist dealer will provide you with Distribution or reproduction of these operating guidance and instruction and assemble your instructions and utilisation or communication of 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. HERCULES GmbH You will find three categories of warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany Tel.: +49 4473 92617 0...
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 Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part stamped on it (see Figure 2). The frame number of pedelecs with the type numbers: can be used to link the pedelec with the owner. Type no.
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 Your specialist dealer will dispose of faulty batteries.  Take faulty batteries to your specialist dealer.  Store the battery in a safety container in a dry place as per special regulations (ADR SV 376, P908) until you dispose of it. Figure 1: Example of a safety container ...
Page 18: Electric Shock
Safety Use correct 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  Always observe the indicated tightening torque Damaged chargers, cables and plug connectors on the screw or in Section 9.4.7.
Page 19: Malfunctions Due To Bluetooth
Safety 2.1.6 Malfunctions due to Bluetooth® If you use the on-board computer with Bluetooth® and/or Wi-Fi®, it may cause interference with other devices, other equipment, aircraft, and medical devices, such as pacemakers and hearing aids. Likewise, it cannot be completely ruled out that you will cause harm to people and animals in the immediate vicinity.
Page 20: Toxic Substances
Safety 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
Safety 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
Safety 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 Vapour Emission
Safety 2.8.3 Battery vapour emission 2.8.4 Battery fire Vapours may be emitted if the battery is damaged The safety electronics may fail if the battery is or used improperly. The vapours may cause damaged or faulty. The residual voltage can respiratory tract irritation.
Page 24: Data Privacy Information
Safety Data privacy information When the pedelec is connected to the diagnosis tool at the specialist dealer’s, 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.
Page 25: Description
Description Description Proper use All checklists and instructions for actions in these reflectors and other components when riding on operating instructions met. Approved accessories public roads. The general laws and the can be installed by specialist staff. regulations for the prevention of accidents and environmental protection in the respective country Use the pedelec when it is in perfect, proper of use must be adhered to.
Page 26: Maximum Permitted Total Weight (Ptw)
Description 3.1.3 Maximum permitted total weight (PTW) The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is • the weight of the fully assembled pedelec • plus body weight • plus baggage Type no.
Page 27: Environmental Requirements
Description 3.1.4 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: Area Of Use
Description 3.1.6 Area of use 3.1.6.1 From model year 2024 onwards as per EN 17406 Average speed Area of use Unsuitability [km/h] Use on normal, paved surfaces where the tyres should maintain 15 ... 25 • Never ride off road. contact with the ground at average speed with occasional jumps.
Page 29: Smartphone And Operating Systems
Description 3.1.7 Smartphone and operating systems The rider needs to register on a PC or their smartphone and create a user account to use all the drive system’s functions. All necessary software updates are downloaded via the app. Settings can also be changed, routes and ride data analysed and premium functions activated in the app among other things.
Page 30: Ebike Flow App
Assembly 3.1.7.1 eBike Flow app A compatible smartphone is required with the and the system controller, and the system eBike Flow app installed to configure the control controller and the mini remote. panels to their full extent. The retailer must ...
Page 31: Model Year 24 Nameplate
EPAC nach EN 15194 0,25 kW / 25 km/h zGG 150 kg / BJ 2024 EPAC XX kg Figure 2: Example HERCULES nameplate No. Designation Description More information The manufacturer uses the CE marking to declare that the pedelec CE marking Section complies with applicable requirements.
Page 32: Components
Description Components 3.3.1 Overview 17 18 20 2122 23 24 Figure 3: Pedelec viewed from right: HERCULES E-Imperial MAX I-F360 used as example Wheel Seat post Chain Saddle Stand Fork Pannier rack Battery and nameplate Guard Rear light Chain guard...
Page 33: Chassis
Description 3.3.2 Chassis The chassis comprises two components: • Frame and • steering system 3.3.2.1 Frame The frame absorbs all forces which act on 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 34: Handlebars
Description 3.3.2.5 Handlebars 3.3.2.6 Fork The stem and handlebars are attached to the top The pedelec is steered using the handlebars. The end of the fork steerer. The axle is fastened to the handlebars are used to support the upper body fork ends.
Page 35: Steering System
Description 3.3.2.7 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.3.2.8 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
Page 36: Handlebars
Description 3.3.2.10 Handlebars The pedelec is steered using the handlebars. The handlebars are used to support the upper body and are used to mount operating and display components (see Section 3.4.1). Figure 11: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
Page 37 Description Parts of a suspension fork Figure 12: Parts of a suspension fork Fork steerer Tyre clearance Sag adjuster Fork crown Tyre height Deflection (suspension fork) Tyre passage width Damper side Quick release Side view Pitch Installation height Fork end (suspension fork) Offset Quick release axle Air suspension side...
Page 38 Description Suspension fork assembly groups A suspension fork can feature up to three different assembly groups: • Compression damper (blue) • Rebound damper (red) • Air suspension or steel spring (orange) Figure 14: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
Page 39 Description Lock The compression can be disabled in any A suspension system absorbs great deal of motor suspension fork. A suspension fork will then and muscle power during rides uphill or on behave like a rigid fork. optimally tarmacked roads. This increases energy consumption and reduces propulsion.
Page 40 Description The suspension fork also deflect quickly and The suspension fork responds instantly to the unhindered when hitting bumps and cushions the impact. The headset and handlebars rise slightly bump when placed at an optimum setting. when absorbing a bump (green line). Traction is retained (blue line).
Page 41 Description Compression dampers When optimally adjusted, the suspension fork counteracts deflection on hilly terrain, stays Compression dampers damp deflection higher in its deflection range and helps to maintain movements, i.e. compression loads. speed when riding on hilly terrain. The compression damper controls the The suspension fork deflects instantly unhindered compression stroke speed or the extent to which and absorbs bumps when the bike hits one.
Page 42 Description Low-speed damper A slow compression speed is generated in the suspension fork when riding over bumps. The low- The low-speed damper (also abbreviated to LSC speed damper controls the suspension fork's from low-speed compression) is a specialised behaviour positively in such riding situations. compression damper.
Page 43: Sr Suntour, Nex E25 Ds-Hlo-700C
Description 3.3.2.12 SR SUNTOUR, NEX E25 DS-HLO-700C Suspension Suspension Steel spring Stanchion distance 116 mm Damping Cartridges General information Deflection Parts list (see Section 11.3) Head tube 1.5" … 1-1/8" Quick release axle Ø 15-100 15QLC32 Offset 44 mm Length 489 mm With mudguard Figure 22: SR SUNTOUR, NEX E25 DS-HLO-700C...
Page 44: Sr Suntour Cartridge Hlo
Description 3.3.2.13 SR SUNTOUR cartridge HLO The SR Suntour HLO cartridge features • a compression damper 2. 2. • a rebound damper Before riding, use the rebound adjuster (fork) (1) to adjust the system to the surface you will ride on. You can use the compression adjuster (2) remote control to open and close the damping.
Page 45: Wheel
Description 3.3.3 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 46 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 47: Rim
Description Bead core 3.3.3.3 Rim The rim is the metal profile on a wheel which holds Tyre carcasses are wrapped around bead cores. the tyre, tube and rim band together. The rim is Wrapping the carcass around both sides creates joined to the hub with spokes.
Page 48: Spoke
Description Presta valve 3.3.3.6 Spoke nipples The Presta valve, also known as the Sclaverand Spoke nipples are screw elements with an internal valve or the French valve, is the narrowest variant thread which fits onto the spoke thread. Fitted of all valves. The Presta valve requires a smaller spokes are tensioned by tightening the spoke hole in the rim, which is why it is especially nipples.
Page 49: Brake
Description 3.3.4 Brake 3.3.4.2 Hydraulic brake A pedelec’s brake system is primarily operated 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 • If the left brake lever is pulled, the brake on the front wheel is applied.
Page 50: Disc Brake
Description 3.3.4.3 Disc brake Figure 34: 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: Backpedal Brake
Description 3.3.4.4 Back-pedal brake Figure 35: Brake system with a back-pedal brake – example Rear wheel rim brake Handlebars with brake lever Front wheel rim brake Pedal Backpedal brake The back-pedal brake is an extra brake. The back- pedal brake stops the rear wheel from moving by pushing the pedals in the opposite direction to the direction of travel.
Page 52: Saddle
Description 3.3.5 Saddle The purpose of the saddle is to absorb body When riding, the rider's body weight is distributed weight, provide support and enable different riding between the pedals, the saddle and the positions. The shape of the saddle thus depends handlebars.
Page 53: Ladies' Saddle
Description 3.3.5.1 Ladies’ saddle 3.3.5.2 Men’s saddle The distance between the ischial tuberosities and In contrast to the female anatomy, men's pubic the pubic symphysis is on average a quarter less bones are at a much steeper angle to one another. in women than in men.
Page 54: Seat Post
Description 3.3.6 Seat post Seat posts are not designed to fasten the saddle but also to adjust exactly to the optimum sitting position. The seat post can: • adjust the seat height in the seat tube • adjust the saddle horizontally with a clamping mechanism and •...
Page 55: Seat Post
Description 3.3.7 Seat post 3.3.7.1 LIMOTEC, A1/A1L Figure 43: Dimensions of LIMOTEC A1 seat post Numbering in drawing Variable type 30.9 Ø/75 mm 25.6 30.9 31.6 Ø/75 mm 25.6 31.6 30.9 Ø/100 mm 25.6 30.9 31.6 Ø/100 mm 25.6 31.6 30.9 Ø/125 mm 25.6 30.9...
Page 56 Description Figure 44: Dimensions of LIMOTEC A1L seat post Numbering in drawing Variable type 30.9 Ø/75 mm 25.6 30.9 31.6 Ø/75 mm 25.6 31.9 30.9 Ø/100 mm 25.6 30.9 31.6 Ø/100 mm 25.6 31.9 34.9 Ø/100 mm 28.6 34.9 30.9 Ø/125 mm 25.6 30.9 31.6 Ø/125 mm...
Page 57: Mechanical Drive System
Description 3.3.8 Mechanical drive system 3.3.8.1 Chain drive layout The pedelec is driven by muscle power, just like a 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 58: Electric Drive System
Description 3.3.9 Electric drive system push assist button is released. The pedelec does not have a separate emergency shut-off button. In The pedelec has an electric drive system in the event of an emergency, the motor can be addition to a mechanical one. stopped by removing the on-board computer.
Page 59: Rechargeable Battery
Description 3.3.9.4 Rechargeable battery The following battery can be built into the pedelec: 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 60: Bosch Purion 200 On-Board Computer
Description 3.3.9.5 BOSCH Purion 200 on-board computer The on-board computer on the handlebars is used as a control panel. It controls the system and all indicators on the display screen using six buttons. Figure 51: BOSCH Purion 200 on-board computer The eBike Flow app can be accessed via Bluetooth®.
Page 61: Description Of Controls And Screens
Description Description of controls and screens 3.4.1 Handlebars Figure 52: Detailed view of handlebars with BOSCH Purion 200, example 1, 4 Handle Air valve cap Rear wheel handbrake (behind handlebars) Sag setting wheel Front wheel handbrake (behind handlebars) Shifter Purion 200 on-board computer MY24H07 - 12_1.0_29.01.2024...
Page 62: Bosch Purion 200 On-Board Computer
Description 3.4.1.1 BOSCH Purion 200 on-board computer The on-board computer on the handlebars is used as a control panel. It controls the system and all indicators on the display screen using six buttons. Figure 53: Overview of BOSCH LED Remote on-board computer Mount Ambient light sensor Selected level of assistance indicator...
Page 63: Selected Level Of Assistance Indicator
Description 3.4.1.2 Selected level of assistance indicator 3.4.1.4 System message The higher the selected level of assistance, the The on-board computer indicates whether a more the drive system assists with pedalling. critical or less critical error has arisen in the drive eMTB mode is available for Performance Line CX system.
Page 64: Ebike Lock
Description 3.4.1.7 eBike Lock eBike Lock can be enabled for every user via the eBike Flow app. A key is saved to the smartphone to unlock the bike. The eBike Lock function is automatically active in the following cases: • when switching off the pedelec via the on-board computer;...
Page 65: Handbrake
Description 3.4.2 Handbrake There is a handbrake on the left and right of the handlebars. Figure 54: 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 66: Shimano Nexus Sl-C7000-5 Twist Grip Shifter
Description 3.4.2.1 SHIMANO NEXUS SL-C7000-5 twist grip shifter Only applies to vehicles with this equipment SHIMANO hub gears feature a NEXUS SL-C7000-5 twist grip shifter with an indicator on the right of the handlebars. Figure 55: SHIMANO NEXUS SL-C7000-5 twist grip shifter Twist grip shifter Gear indicator You change gears by turning the twist grip shifter.
Page 67: Shimano, Deore Sl-M4100-R
Description 3.4.2.2 SHIMANO, DEORE SL-M4100-R Only applies to vehicles with this equipment On the right of the handlebars, you will find the SHIMANO DEORE SL-M4100-R gear shift unit. The gear shift unit features 2 shifters. Figure 56: SHIMANO DEORE SL-M5130-R10 Down button (gear shift) Up button (gear shift) Gear indicator...
Page 68: Suspension And Damping
Description 3.4.3 Suspension and damping 3.4.3.1 SR SUNTOUR air valve (fork) and sag setting wheel (fork) Model AIR EQ COIL Adjustable COIL Air valve (fork) Air valve (fork) Sag setting wheel Sag setting wheel Suspension Air suspension Air suspension Steel spring Steel spring Durolux Auron...
Page 69: Rechargeable Battery
Description 3.4.4 Rechargeable battery 3.4.4.1 Battery level indicator screen The five green LEDs on the battery level indicator show the charge level when the battery is Each battery has its battery level indicator: switched on. Each LED represents 20% of battery capacity.
Page 70: Fork Lock
Description 3.4.5 Fork lock Only applies to vehicles with this equipment The suspension in suspension forks is adjusted 3.4.5.1 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 71: Technical Data
Technical data Technical data 3.5.1 Pedelec Power output/system 250 W (0.25 kW) Shut-off speed 25 km/h Charging temperature 0 °C … +45 °C Operating temperature -5 °C … +40 °C Storage temperature +10 °C … +50 °C Service life 7 years Weight See Section 4.1 See Section 3.1.3...
Page 72 Technical data 3.5.2.0.1 BOSCH, BDU3320 | BDU3340 | BDU3360 Figure 60: BOSCH, BDU3320 | BDU3340 | BDU3360 Motor Active Line Active Line Plus Performance Line Product code BDU3320 BDU3340 BDU3360 Continuous power rating [W] Maximum torque on drive [Nm] Nominal voltage [V] Operating temperature -5 ...
Page 73 Technical data Details on noise emissions from the drive unit The A-weighted emission sound pressure level of the drive unit is < 70 dB(A) in normal mode. If the e-bike is moved without authorisation, the drive unit in the frame sounds an alarm as part of the <eBike alarm>...
Page 74 Technical data 3.5.2.0.2 BOSCH, BDU3740 | BDU3741 | BDU3742 | BDU3743 | BDU3760 | BDU3761 | BDU3780 | BDU3781 Figure 61: BOSCH, BDU3740 | BDU3741 | BDU3742 | BDU3743 | BDU3760 | BDU3761 | BDU3780 | BDU3781 Motor Cargo CX Race Edition Speed Product code BDU3740 | BDU3741...
Page 75 Technical data Details on noise emissions from the drive unit The A-weighted emission sound pressure level of the drive unit is < 70 dB(A) in normal mode. If the e-bike is moved without authorisation, the drive unit in the frame sounds an alarm as part of the <eBike alarm>...
Page 76 Technical data 3.5.2.0.3 BOSCH, Purion 200 [BRC 3800] (EB13.200.03V) Figure 62: BOSCH, Purion 200 [BRC 3800] (EB13.200.03V) On-board computer Purion 200 Product code BRC 3800 Protection class IP55 Dimensions (without fastening) 85 × 54 × 60 Weight [kg] Charging temperature 0 ...
Page 77 Technical data 3.5.2.0.4 BOSCH, PowerPack 300 | 400 | 500, PowerTube 400 | 500 | 625 Figure 63: BOSCH, PowerPack 300 | 400 | 500, PowerTube 400 | 500 | 625 Rechargeable battery PowerPack 300 Product code BBS245, standard battery BBR245, pannier rack battery Nominal voltage [V=] Nominal capacity [Ah]...
Page 78 Technical data Rechargeable battery PowerPack 500 Product code BBS275, standard battery BBR275, pannier rack battery Nominal voltage [V=] Nominal capacity [Ah] 13.4 Energy [Wh] Operating temperature [°C] -5 ... +40 Storage temperature [°C] +10 ... +40 Permitted charging temperature range [°C] 0 ...
Page 79 Technical data Rechargeable battery PowerTube 625 Product code BBP290, horizontal BBP291, vertical Nominal voltage [V=] Nominal capacity [Ah] 16.7 Energy [Wh] Operating temperature [°C] -5 ... +40 Storage temperature [°C] +10 ... +40 Permitted charging temperature range [°C] 0 ... +40 Approx.
Page 80: Tyres
Description 3.5.3 Tyres 3.5.3.1 SCHWALBE puncture protection level V-GUARD Inserts The V-Guard puncture protection Webbing Rubber insert belt comprises of lightweight, cut- insert Combination resistant fibres. Its webbing ensures highly effective puncture resistance SmartGuard® for lightweight race and tour tyres. DualGuard Tubeless Easy Double Defense®...
Page 81: Torque
Technical data 3.5.4 Torque Model Torque Tool Axle Conventional axle nut 35 … 40 Nm… 15 mm spanner SR SUNTOUR screw-on axle 12AH2 Axle 8 … 10 Nm 6 mm hex bit Securing screw 5 … 6 Nm 5 mm hex bit SR SUNTOUR screw-on axle 15AH2 Axle...
Page 82 Technical data BOSCH System Controller Attachment screw 0.5 Nm Torx® T10 BOSCH Mini Remote Attachment screw 0.4 Nm (not 0.6 Nm, as written on mini-remote) 3 mm hex bit SHIMANO SC-E5003 0.8 Nm 3 mm hex bit Attachment screw Brake linings SHIMANO Hex key, 3 mm Circlip...
Page 83 Technical data Brake disc SHIMANO for centre lock type TL-LR15 Attachment screw, quick TL-FC36/TL-LR11 release 40 … 50 Nm Adjustable spanner SHIMANO for centre lock type Attachment screw, nut TL-LR10 version 40 … 50 Nm Screw wrench SHIMANO for 5-hole version Attachment screws 2 …...
Page 84 Technical data Suspension fork Intend Edge Double bridge screw 12 Nm SR SUNTOUR Suspension side, top, plastic 5 Nm SR SUNTOUR Suspension side, top, aluminium 20 Nm SR SUNTOUR Suspension side, bottom 10 Nm Hex bit (torque) SR SUNTOUR Suspension side, bottom 8 Nm Aluminium nut (torque) SR SUNTOUR...
Page 85 Technical data SRAM RockShox, Lyrik, ButterCup housing guide rod end plate - end plate to guide rod - air suspension and damper 3.3 Nm Torx® T25 SRAM RockShox, Lyrik, ButterCup housing (top) to ButterCup housing (bottom) – air suspension and damper 3.3 Nm 23 mm spanner head SRAM RockShox...
Page 86 Technical data Chainring FIT, Brose FIT Crank start spider lockring 28 Nm ISIS bottom bracket axle tool FIT, Panasonic FIT Crank star screws 13 Nm Hex key, 5 mm FIT, Panasonic FIT Crank start spider lockring 40 Nm ISIS bottom bracket axle tool FIT, Panasonic FIT Crank star screws 13 Nm...
Page 87 Technical data SHIMANO, HOLLOWTECH Ii/two-part crank set 0.7 … 1.5 Nm TL-FC16 / TL-FC18 SHIMANO, HOLLOWTECH Ii/two-part crank set Screw for left-hand crank arm 12 … 14 Nm Hex key, 5 mm SHIMANO, OCTALINK type Linker for adapter and main body 50 …...
Page 88 Technical data ENVIOLO Interface lock nut 10 ... 15 Nm ENVIOLO Tapered nut 9 .. 10 Nm ENVIOLO Initial speed ring 1.0 Nm ENVIOLO Screw for control cable cover 0.2 ... 0.3 Nm (hand-tight) ROHLOFF, 14/500 Bayonet lock/cable drum screws 1.5 Nm 2 mm hex bit ROHLOFF, 14/500...
Page 89 Technical data ROHLOFF, 14/500 End stop 3 Nm Torx® TX 20 ROHLOFF, 14/500 Cable guide 6 Nm 4 mm hex bit SHIMANO quick release version FH-M3050, FH-M4050, 40 Nm Adjustable spanner and special tool TL-LR15 FH-MT200-B, FH-MT400, (SHIMANO) FH-MT400-B, FH-MT500, FH-MT500-B, FH-MT510, FH-MT510-B, FH-RM33, FH-RM35,...
Page 90 Technical data Pedal Pedal, conventional 33 … 35 Nm Screw wrench, 15 mm SHIMANO Attachment screw 35 … 55 Nm Screw wrench, 15 mm Seat post BY.SCHULZ G1 M8 seat clamp screw 20 … 24 Nm M5 fixing grub screws 3 Nm 2.5 mm hex bit BY.SCHULZ G2...
Page 91 Technical data SHIMANO XTR SL-M9100 Attachment screw 3 Nm 4 mm hex bit SRAM AXS controller Collar attachment screw 2 Nm Torx® T25 Rear derailleur SHIMANO for MTB/trekking Attachment screw, standard type 8 … 10 Nm Hex key, 5 mm SHIMANO for MTB/trekking Attachment screw with bracket...
Page 92 Technical data SHIMANO for racing bicycles Hex key, 5 mm/ Attachment screw 5 … 7 Nm Screw wrench, 9 mm SHIMANO for racing bicycles Attachment screw, Bowden Hex key, 5 mm/ cable 6 … 7 Nm Underride guard Socket wrench, 8 mm FIT, Brose Hex key, 4 mm Attachment screws...
Page 93: Transporting And Storing
About these operating instructions Transporting and storing Weight and dimensions for transportation # Not yet available when the instructions were produced Designated handles, lifting points The box does not have any handles. MY24H07 - 12_1.0_29.01.2024...
Page 94: Transportation
Transporting and storing Transportation 4.3.2 Transporting the pedelec 4.3.2.1 By car CAUTION Bicycle rack systems which use the handlebars or frame to hold the pedelec in an upside-down Crash caused by unintentional activation position exert inadmissible forces on its There is a risk of injury if the drive system is components during transportation.
Page 95: By Local Transport
Transporting and storing 4.3.4 Transporting the battery 4.3.2.3 By local transport Batteries are subject to hazardous goods You can normally take pedelecs on local public regulations. Undamaged batteries may be transport, e.g. by bus or suburban rail, if you transported by private persons in road traffic. purchase a bike ticket.
Page 96: Storing
Transporting and storing Storing  Always store pedelec, battery, on-board New battery computer, display and charger separately. Inspect battery for damage after delivery.  Storage temperature +10 °C … +40 °C  If batteries are faulty, observe instructions in Humidity 30%…85% Handling a damaged or faulty battery during storage and disposal (see Section 2.1.1).
Page 97: Break In Operation
Transporting and storing 4.4.4 Break in operation 4.4.4.1 Preparing for a break in operation 1 The pedelec needs to be cleaned with a damp Notice cloth and preserved with wax spray. Never wax the friction surfaces of the brake. Batteries discharge if they are not used. If the 2 Have the specialist dealer carry out battery is stored for a longer period of time when maintenance and basic cleaning and apply...
Page 98: Assembly 5.1 Unpacking
Assembly Assembly Scope of delivery WARNING 1 × pre-assembled pedelec  Risk of eye injury 1 × front wheel  Problems may arise if components are set 2 × pedals  incorrectly. They may cause serious injuries to 2 × quick releases (optional) ...
Page 99: 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. It makes sense to prepare each pedelec so that it is fully ready for use immediately after being assembled.
Page 100: Adjusting The Suspension System To Body Weight
Assembly 5.3.2 Adjusting the suspension system to body weight Not included in price 5.3.2.1 Adjusting SR Suntour suspension elements Seat post and forks are components that may be § Not included in price replaced after approval by the vehicle or parts manufacturer.
Page 101: Preparing The Wheel
Assembly 5.3.3 Preparing the wheel There is an arrow on the sides of the tyres with the • The FRONT rotation direction arrow indicates the recommended direction of rotation for the front inscription ROTATION to show the direction of wheel. rotation.
Page 102: Installing The Wheel In The Suntour Fork
Assembly 5.3.4 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.4.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this equipment Before installing the wheel, ensure that the O-ring 4 Insert the securing screw on the non-drive ...
Page 103: Mm Cross Axle
Assembly 5.3.4.2 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 104 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 77: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 105: Q-Loc Quick Release
Assembly 5.3.4.3 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 106: Adjusting The Limotec Seat Post
Assembly 5.3.5 Adjusting the LIMOTEC seat post Only applies to pedelecs with this equipment The rider’s body weight exceeds or falls below the  seat post’s functional weight. 1 Order new Limotec seat post with suitable functional weight. 2 Remove existing seat post. Replacing Limotec A1 and A5 3 Use the seat height formula to calculate the optimum seat post height for leg length:...
Page 107: Fitting The Pedals
Assembly 5.3.6 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.
Page 108: Checking The Stem And Handlebars
Assembly 5.3.7 Checking the stem and handlebars 5.3.7.1 Checking the connections 5.3.7.3 Checking the 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 109: 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 110 Operation Notice CAUTION Heat or direct sunlight can cause the tyre pressure Crash caused by material fatigue to increase above the permitted maximum pres- Intensive use can cause material fatigue. A com- sure. This can destroy the tyres. ponent may suddenly fail in case of material ...
Page 111: 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 112: Error Message
Operation Error message 6.3.1 On-board computer The on-board computer indicates whether a  Press selection button. critical or less critical error has arisen in the drive  The error is acknowledged and the indicator for system. the selected level of assistance displays the colour for the configured level of assistance The error messages generated by the drive permanently.
Page 113 Operation Description Method of resolution If a battery fault is detected, two  Contact specialist LEDs will flash on the battery dealer. level indicator. Code: No LEDs will light up if there is Check all plug connections. no power. Check contacts on the battery for dirt.
Page 114: Instruction And Customer Service
Operation Instruction and customer service 6.5.1 Preparing The supplying specialist dealer will provide 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 115: Determining The Sitting Position
Operation 6.5.2 Determining the sitting position The starting point for a comfortable posture is the Position on roadster Position on city bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.
Page 116 Operation 6.5.3 Seat post 6.5.4 Saddle 6.5.3.1 Adjusting the seat post to body weight 6.5.4.1 Replacing the saddle Not included in price Not included in price Seat post are components that may be replaced Saddles are components that may be replaced §...
Page 117 Operation 6.5.4.2 Determining the saddle shape Ladies’ saddle To distribute the pressure optimally over the female bone structure in the seat area, a ladies’ saddle should: • have a relief opening far to the front • have a wide V-shaped saddle edge. Figure 88: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
Page 118 Operation 6.5.4.3 Determining the minimum saddle width With corrugated cardboard With a 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. seat.
Page 119 Operation Using calculation Depending on the position, the following value is added to the minimum saddle width. Position on roadster + 4 cm Position on city bike + 3 cm Position on trekking bike + 2 cm Position on sports bike + 1 cm Triathlon/time trials + 0 cm...
Page 120 Operation 6.5.4.6 Straightening the saddle 4 Take a test ride.  Pedelec riders sit straight on the saddle at an  Position saddle in direction of travel. In doing optimal saddle height. so, align the tip of the saddle with the top tube. •...
Page 121 Operation 6.5.4.9 Adjusting the saddle position The saddle can be shifted on the saddle frame. The right horizontal position ensures an optimal leverage position for legs. This prevents knee pain and painful incorrect pelvis positions. If you have displaced the saddle more than 10 mm, you need to adjust the saddle height again since both settings affect one another.
Page 122 Operation 6.5.4.10 Adjusting the saddle tilt The saddle tilt must be adjusted to the seat height, the saddle and handlebar position, and the saddle shape to ensure an optimum fit. The seating position can be optimised in this way if needed. The saddle prevents pedelec riders from slipping backwards or forwards when placed in a horizontal position.
Page 123 Operation 6.5.5 Handlebars 6.5.5.1 Replacing the 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 124 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 seating position (see Section 6.5.2), determine the angle of the upper body and the upper arm. 2 Tension the back muscles when adjusting the handlebars.
Page 125 Operation 6.5.6 Stem 6.5.6.1 Replacing the stem 2 Pull out the handlebars to the required height. Observe minimum insertion depth. Not included in price Handlebar-stem units are components that may § be replaced after approval by the vehicle or parts manufacturer.
Page 126 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 127 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. Only handles that are approved for use on e-bikes may be used to replace the existing ones.
Page 128 Operation 6.5.8 Tyres 6.5.8.1 Replacing tyres As a general rule, wide tyres are operated at a lower tyre pressure. They provide the option of Not included in price exploiting the advantages of the lower tyre pressure without the serious disadvantages it Different tyres need to be used when the area of causes with regard to wear, rolling resistance and §...
Page 129 Operation 2 Perform a visual check on tyres. Figure 109: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 110: Far too little tyre pressure MY24H07 - 12_1.0_29.01.2024...
Page 130 Operation 6.5.9 Brake 6.5.9.3 Changing the handbrake position The handbrake grip distance can be adjusted to ensure that it can be reached more easily. The Having the handbrake in the correct position pressure point can also be adjusted to the pedelec prevents the rider from stretching their wrist too rider’s preferences.
Page 131 Operation 6.5.9.4 Changing the handbrake inclination 2 Set the brake lever angle as indicated in the angle table. The nerves that pass through the carpal tunnel are connected to the thumb and the index and middle fingers. An excessively steep or 20 –...
Page 132 Operation 6.5.9.6 Setting the grip distance for a MAGURA handbrake disc brake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the rider’s requirements. Such adjustment does not WARNING affect the pressure point or the position of the Crash caused by incorrectly set grip distance brake linings.
Page 133 Operation 6.5.9.7 Grip distance on Magura HS11 handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the Use a 2.5 mm wrench to turn the setting screw (1)  to adjust the grip distance. rider’s requirements.
Page 134 Operation 6.5.9.8 Grip distance on MAGURA HS22 handbrake Only applies to pedelecs with this equipment Use a T25 TORX® wrench to turn the setting  screw (2) to adjust the grip distance. WARNING 1 Pull the handbrake gently and hold. Crash caused by incorrectly set grip distance ...
Page 135 Operation 6.5.9.9 Magura HS33 handbrake grip distance Only applies to pedelecs with this equipment The handbrake position can be adjusted to the  The handbrake will move closer to the handlebar grip. rider's requirements. Such adjustment does not affect the pressure point or the position of the ...
Page 136 Operation 6.5.9.10 MAGURA handbrake pressure point Only applies to pedelecs with this equipment The pressure point setting is adjusted using the twist knob. WARNING  Turn the twist knob towards the plus (+) Brake failure due to incorrect setting symbol. If the pressure point is set with brakes where the ...
Page 137 Operation 6.5.9.11 Adjusting the grip distance on a SHIMANO 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 138 Operation 6.5.9.12 Setting the grip distance on a TEKTRO handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the Notice rider’s requirements.  Undo 2 mm setting screw anti-clockwise. If the setting screw is fully removed, components inside the handbrake will also be permanently ...
Page 139 Operation 6.5.10 Control panel and gear shift The control panel and gear shift must be adjusted to the rider's needs. 1 Undo attachment screw. 2 Place control panel or gear shift into the position where the rider can use the control panel or the shifter with their thumb and/or index finger.
Page 140 Operation 6.5.11 Gear shift 6.5.11.1 Replacing an ENVIOLO gear shift A compatible smartphone with the app is required to use all the app's functions. Not included in price You can use enviolo AUTOMATiQ to establish a Bluetooth® connection between the smartphone All gear shift components (rear derailleur, shifter, §...
Page 141 Operation 4 The enviolo AUTOMATiQ app will search for available devices automatically. 5 Select the activated hub interface on the smartphone.  The Enviolo hub is now paired with the smartphone. 6.5.11.3 Adjusting pedalling frequency in ENVIOLO AUTOMATiQ mode Only applies to pedelecs with this equipment The gear switching system adjusts to the rider's pedalling frequency on pedelecs equipped with ENVIOLO AUTOMATiQ mode.
Page 142 Operation 6.5.12 Suspension and damping Suspension and damping can be adjusted to the  Follow the correct order for adjustment. rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Sequence Adjustment Section Suspension fork Rear frame damper...
Page 143 Operation 6.5.13.1 Adjusting the sag for SR SUNTOUR air suspension fork Only applies to pedelecs with this equipment 1 Turn the air valve cap (see Section 3.4.3.1) 3 Pump air suspension to the required pressure anti-clockwise away from the air valve level.
Page 144 Operation Recommended air pressure [psi] < 55 40… 55 40… 55 40… 55 40… 55 40… 55 40… 55 55… 65 … … 55… 65 55… 65 55… 65 55… 65 65… 75 … … 65… 75 65… 75 65… 75 65…...
Page 145 Operation Adjusting preload internally  Only your specialist dealer may make an internal adjustment to the preload. The air volume spacers can be replaced on some fork models. This changes the value for the centre stroke and the bottom-out (bounce) resistance. ...
Page 146 Operation Aion35 Zeron35 Axon32 Mobie34-air Mobie45-air Rubber volume 4.3cc 4.3cc space Deflection [mm] … … … … … … … … … … … … … … … … … … … … … … … … … … … …...
Page 147 Operation 6.5.13.2 Adjusting the sag for the SR SUNTOUR steel suspension fork Only applies to pedelecs with this equipment You can pre-tension the steel suspension to riding style. It is not the coil spring hardness which adjust to the rider's weight and their preferred is adjusted;...
Page 148 Operation 6.5.14 Adjusting the suspension fork rebound damper Only applies to pedelecs with this equipment Rebound damping is adjusted to the rider’s body weight, spring stiffness, deflection, the terrain and the pedelec rider's preferences. If the air pressure or spring stiffness increases, the extension and rebound speeds also increase.
Page 149 Operation 6.5.14.1 Adjusting the SR Suntour rebound damper suspension fork Only applies to pedelecs with this equipment Figure 124: Example of SR SUNTOUR rebound adjuster (suspension fork) (1) Adjusting the suspension fork sag (see  Section 6.5.13). 1 Turn the rebound adjuster (suspension fork) clockwise to the closed position until it stops.
Page 150 Operation 6.5.15 Riding light 6.5.15.1 Replacing the headlight 6.5.15.2 Replacing the rear light and (spoke) reflector Not included in price Not included in price Headlights may only be replaced after approval § The rear light and (spoke) reflector may be §...
Page 151 Operation 6.5.15.4 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 152 Operation 6.5.16 On-board computer 7 Follow the instructions on the display. A smartphone with the eBike Flow application is required to use all drive system functions. The  The user data will be synchronised once the pedelec is connected to the app via a Bluetooth® pairing process is complete.
Page 153 Operation Once the lock function is switched on, the pedelec 6.5.16.7 Securing the on-board computer (optional) can only be put into use if: It is possible to secure the on-board computer so • the configured smartphone is switched on, that it cannot be removed. The locking plate does •...
Page 154 Operation 6.5.16.9 Adjusting the on-board computer You can use the forward button (1) and back button (2) to access the different user interfaces Notice with information on ride values even when riding. This means both hands remain on the handlebars while you are cycling.
Page 155 Operation 6.5.16.10Adjusting the on-board computer 6.5.16.11Selecting the the language 1 Open <System> menu item. The pedelec is stationary. You cannot open and  adjust the settings while riding. 2 Open < Language> sub-menu item. Inserting the display.  3 Follow the instructions on the on-board computer.
Page 156 Operation 6.5.16.16Reset settings 1 Open <System> menu item. 2 Open <Settings reset> sub-menu item. 3 Follow the instructions on the on-board computer.  All settings are reset to the factory settings. All user data has been cleared. MY24H07 - 12_1.0_29.01.2024...
Page 157 Operation 6.5.17 Adjusting the on-board computer 5 Release the On-Off button. A smartphone with the eBike Flow application is required to use all drive system functions. The 6 Accept the connection prompt in the app. pedelec is connected to the app via a Bluetooth® 7 Follow the instructions on the display.
Page 158 Operation 6.5.17.5 Setting up the lock function (optional) 6.5.17.6 Inserting the battery The user account can be used to activate the lock 1 Use a slotted-head screwdriver to pry open the function. This will create a digital key on the battery compartment lid on the display rear.
Page 159 Operation 6.5.17.7 Inserting the display 6.5.17.9 Securing the on-board display (optional) 1 Insert the battery compartment nub (1) into the It is possible to secure the on-board computer so bracket mount recess (2). that it cannot be removed. Inserting the blocking 2 Gently press display downwards.
Page 160 Operation 6.5.17.10 Adjusting the on-board computer You can use the forward button (1) and back button (2) to access the different user interfaces Notice with information on ride values even when riding. This means both hands remain on the handlebars while you are cycling.
Page 161 Operation 6.5.17.11 Adjust on-board computer 6.5.17.12 Selecting the language The pedelec is stationary. You cannot open and 1 Open the <Language> submenu.  adjust the settings while riding. 2 Press the select button briefly until the Inserting the display.  required language is displayed.
Page 162 Operation 6.5.17.17 Adjusting the backlight 1 Open <Backlight> submenu. 2 Press the Select button briefly to select the duration of the backlight after pressing a button. 3 Press the Back button.  You now exit the submenu. The backlight has been set.
Page 163 Operation Accessories CAUTION We recommend a parking stand into which either the front wheel or rear wheel can be inserted Crash caused by improper handling securely for pedelecs which do not have a kickstand. The following accessories are When using child seats, the pedelec's handling recommended: characteristics and stability change considerably.
Page 164 Operation 6.6.3 Pannier rack The specialist dealer will provide instruction on how to handle the pedelec and the child seat. The specialist dealer will advise on choosing a 6.6.2 Trailer suitable pannier rack. The specialist dealer must install the pannier rack the first time to ensure that it is safely fitted.
Page 165 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 166 Operation Preparing a folding bicycle ready for use 6.9.0.2 Folding out the pedal WARNING 1 Push the pedal against the pedal crank with the foot from the front. Risk of fire and explosion due to faulty battery If the bicycle is not prepared correctly ready for use, this may result in the rider falling and sustaining serious injury.
Page 167 Operation 6.10 Using the battery Switching off the electric drive system (see 6.10.1.2 Inserting the integrated battery  Section 6.13.2). The key is inserted in the lock.  The lock is unlocked.  6.10.1 Using the integrated battery Only applies to pedelecs with this equipment 6.10.1.1 Removing the integrated battery Figure 144: Inserting the integrated battery 1 Place the battery into the lower mount with the...
Page 168 Operation 6.10.2 Frame battery 1 Remove the cable connection cover if necessary. Only applies to pedelecs with this equipment 2 Connect the mains plug of the charger to a 6.10.2.1 Removing the frame battery normal domestic, grounded socket. Connection data 230 V, 50 Hz Notice ...
Page 169 Operation 6.11 Straightening the quickly 6.12 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 170 Operation 6.14.1 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 171 Operation 6.16 Setting the saddle height with the 6.18 Using the handlebars remote control  Wear heavily padded cycling gloves. Only applies to pedelecs with this equipment  This helps protect sensitive areas of your palms. 6.16.1 Lowering the saddle ...
Page 172 Operation 6.18.2 Using bar ends Only applies to pedelecs with this equipment Bar ends can be added to normal handlebars. Adjustable bar ends feature a ball joint which you can use to choose the optimum position as required.  Adjust bar ends correctly. To do so, your hand, elbow and shoulder must be in line with one another when the hand takes hold of the bar ends.
Page 173 Operation 6.19 Using the electric drive system with BOSCH Purion 200 6.19.1 Switching on the electric drive 6.19.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in CAUTION normal mode or reaches a speed of 25 km/h, the drive system switches off the assistance system.
Page 174 Operation 6.19.3 Using the Purion 200 on-board 6.19.3.3 Using the riding light computer The drive system needs to be already switched  on to turn on the riding light. Notice  Never use on-board computer, the display or the display mount as a handle. If the on-board computer, display or display mount are used to lift the pedelec, components can become irreparably damaged.
Page 175 Operation 6.19.3.5 Using the headlamp flasher 6.19.3.7 Using the push assist system Another road user is putting themselves or others  at risk. CAUTION  Press the main beam switch twice quickly. Injury from pedals or wheels  The other road user has been alerted that they are putting themselves or others at risk.
Page 176 Operation 1 Press Push assist button for longer than 6.19.3.8 Selecting the level of assistance 1 seconds. Hold down the button. The control panel is used to set how much the electric drive should assist the rider when  The battery level indicator goes out and a white running light in the direction of travel indicates pedalling.
Page 177 Operation 6.20 Using the brake 6.20.1 Using the handbrake Only applies to pedelecs with this equipment WARNING Crash caused by brake failure Oil or lubricant on the brake disc in a disc brake or on the rim of a rim brake can cause the brake to fail completely.
Page 178 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 179 Operation 6.21.2 Using a SHIMANO hub gear Only applies to pedelecs with this equipment CAUTION Crash caused by incorrect use If the rider applies too much pressure on the pedals during a gear change and activates the shifter or changes several gears at a time, their feet may slip from the pedals.
Page 180 Operation 6.21.3 Using eShift 6.21.3.2 Using eShift with manual SHIMANO DI2 hub gears eShift refers to the integration of electronic gear Only applies to pedelecs with this equipment shift systems into the electric drive system. The new gear is shown briefly on the on-board 6.21.3.1 Using eShift with SHIMANO DI2 computer each time it is changed.
Page 181 Operation 6.22 Use suspension and damping 6.22.1 Locking the suspension A suspension system is designed to cushion and Some suspension forks thus feature a lockout on compensate for unevenness on a surface whether the crown or a remote lockout activated on the the user is riding on bumpy cycle paths, dirt roads handlebars.
Page 182 Operation 6.22.2 Adjusting the suspension fork compression damper The compression damper allows the rider to make When placed at an optimum setting, the quick adjustments to the suspension behaviour of suspension fork counteracts deflection on hilly the suspension fork to adapt to changes in terrain. terrain, remains higher in its deflection range and It is intended for adjustments made during the helps maintain speed when riding on terrain hilly...
Page 183 Operation 6.22.2.1 Using SR Suntour high-speed compression damping A high speed is generated in the suspension fork, The settings on the high-speed damper control e.g. on a mogul slope or during landing after a the suspension behaviour of the fork during jump.
Page 184 Operation 6.22.2.2 Using the SR Suntour low-speed compression damping Low-speed movement in the suspension fork is The settings on the high-speed damper control caused, for example, by riding over bumps. the suspension behaviour of the fork • during staggered jumps •...
Page 185 Operation 6.23 Adjusting the suspension fork  Adjusting the suspension and damping on the suspension fork or on the remote control (suspension fork) while riding: Position Suspension Downhill rides and uneven terrain Open or OPEN Flat, hilly, even or slightly bumpy terrain or Threshold or uneven roads medium...
Page 186 Operation 6.23.1.1 Locking the SR SUNTOUR suspension fork Only applies to pedelecs with this equipment LORC-PCS LORC Table 51: Lockout on the fork crown on SR Suntour suspension forks  Turn lockout (1) on the fork crown clockwise to  Turn lockout (1) on the fork crown LOCK.
Page 187 Operation 6.23.2 Adjusting the SR Suntour compression damper Figure 166: 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 188 Operation 6.24 Folding 2 Fold the pedal against the pedal crank. Notice  Never crush or bend Bowden cables, electric cables or brake cables when folding. 6.24.1 Folding up your pedelec Only applies to pedelecs with this equipment The pedelec is folded in eight steps. Figure 168: Folding the pedal up (I) or down (II) 1 Switch off electric drive system (see 6.24.1.2 Folding up the stem, version I...
Page 189 Operation 6.24.1.3 Folding up the stem, version II CAUTION Only applies to pedelecs with this equipment Crash caused by using the opened locking 1 Open the clamping lever on the stem quick lever incorrectly release. The frame will suddenly fold together while the 2 Push the unlocking knob.
Page 190 Operation 6.25 Parking 6 Remove battery to protect against theft (see Notice Section 6.6.1.1). 7 Clean and service pedelec after every ride; see Heat or direct sunlight can cause the tyre pressure Section 7.2. to increase above the permitted maximum pressure.
Page 191 Operation 6.25.1 Screwing in the quickly adjustable 6.25.2 Folding up the pedal stem  Clean the pedal (see Section 7.2.4). Only applies to pedelecs with this equipment 1 Use two fingers to pull the pedal folding latch (1) Screw in the quickly adjustable stem to save downwards and hold in position.
Page 192 Operation 6.25.3 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 193 Cleaning, maintenance and inspection Cleaning, maintenance 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 194 Cleaning, maintenance 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 on-board computer See Section 7.3.1  Clean hub See Section 7.3.12  Clean on-board computer See Section 7.3.1 ...
Page 195 Cleaning, maintenance and inspection Checklist: Tasks performed at least every six months Checklist: Tasks performed at least every six months (or every 1,000 km) (or every 1,000 km) Check Bowden cables gear Servicing the stem See Section 7.4.6   See Section 7.5.10.2 shift...
Page 196 Cleaning, maintenance 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 197 Cleaning, maintenance and inspection Before each ride 7.1.5 Checking the pannier rack Complying with these cleaning instructions is the 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 198 Cleaning, maintenance and inspection 7.1.9 Checking the suspension seat post  Deflect and let the suspension seat post rebound.  If you hear unusual noises when the suspension seat post deflects and rebounds, or it yields without any resistance, take pedelec out of service.
Page 199 Cleaning, maintenance and inspection After each ride 7.2.4 Cleaning the pedals Complying with these cleaning instructions is the 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 200 Cleaning, maintenance and inspection Basic cleaning 7.3.2 Cleaning the battery Complying with these basic cleaning instructions 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 201 Cleaning, maintenance and inspection 7.3.4 Cleaning the frame, fork, pannier 7.3.7 Cleaning the handles rack, 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.
Page 202 Cleaning, maintenance and inspection 7.3.9 Cleaning the saddle 7.3.12 Cleaning the 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 203 Cleaning, maintenance and inspection 7.3.16 Cleaning the brake 7.3.14.1 Cleaning the shifter 7.3.16.1 Cleaning the handbrake  Carefully clean shifter with a damp, soft cloth.  Carefully clean the handbrake with a damp, 7.3.15 Cleaning the cassette, chain wheels soft cloth. and front derailleur 7.3.17 Cleaning the brake disc...
Page 204 Cleaning, maintenance and inspection 7.3.19 Cleaning the chain Notice  Never use aggressive (acid-based) cleaners, rust removers or degreasers when cleaning the chain.  Never use gun oil or rust remover spray.  Never use chain cleaning devices or chain cleaning baths.
Page 205 Cleaning, maintenance and inspection Maintenance 7.4.1 Maintain frame Complying with these servicing instructions is the 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 206 Cleaning, maintenance and inspection 7.4.3 Maintain pannier rack 7.4.6 Maintaining the stem 1 Dry pannier rack with a cloth. 1 Spray painted and polished metal surfaces 2 Spray pannier rack with spray wax and leave to with wax spray and leave to dry. dry.
Page 207 Cleaning, maintenance and inspection 7.4.8 Maintaining the handles Maintaining the 7.4.9.2 carbon seat post Maintaining 7.4.8.1 rubber handles 1 Apply talcum powder to sticky rubber handles. Notice Notice Rain and puddle water can cause contact  Never apply talcum powder to leather or foam corrosion if carbon seat posts are used in an handles.
Page 208 Cleaning, maintenance and inspection 7.4.12 Maintaining the hub 7.4.14 Maintaining the gear shift Maintaining 7.4.14.1 the rear derailleur articu- lated shafts and jockey wheel 1 Apply wax spray especially around the spoke holes. In doing so, ensure that no wax is applied to brake parts.
Page 209 Cleaning, maintenance and inspection 7.4.16 Maintaining the chain 7.4.16.1 Maintaining the chain and all-round chain guard Place newspaper or paper towels underneath to  Place newspaper or paper towels underneath to  collect chain oil. collect chain oil. 1 Lift rear wheel. 1 Lift rear wheel.
Page 210 Cleaning, maintenance and inspection 7.4.18 Maintaining the brake 7.4.18.1 Maintaining the handbrake Notice  Never treat brake handbrake 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 211 Cleaning, maintenance 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 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 212 Cleaning, maintenance and inspection Dunlop valve Schrader valve Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment The tyre pressure cannot be measured on the It is recommended to use an air pump at a filling ...
Page 213 Cleaning, maintenance 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 214 Cleaning, maintenance 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 215 Cleaning, maintenance 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 2 If any brake fluid leaks from anywhere, take hydraulic fluid in the brake cable reduce the...
Page 216 Cleaning, maintenance 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. ...
Page 217 Cleaning, maintenance 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 218 Cleaning, maintenance 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 219 Cleaning, maintenance and inspection 7.5.3 Checking the chain 3 Check the chain tension at three to four points.  If the deviation is greater than 20 mm, tighten  Check chain for rust, damage and chain links chain. that are difficult to move. ...
Page 220 Cleaning, maintenance and inspection 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 190: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 185: Example of a KMC gauge Figure 191: Lower gauge to the left Figure 186: Example of a SHIMANO gauge...
Page 221 Cleaning, maintenance and inspection 7.5.4 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 222 Cleaning, maintenance and inspection 7.5.5 Checking the stem 7.5.8 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 223 Cleaning, maintenance and inspection 7.5.10 Checking the gear shift 4 Check that there is clearance between the chain tensioner and spokes. 1 Check that all gear shift components are free of  If there is no clearance or the chain scrapes damage.
Page 224 Cleaning, maintenance and inspection 7.5.10.5 Adjusting the ROHLOFF hub 7.5.10.6 Adjusting the cable-operated gear shift, dual-cable Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment 1 Check whether shift cable tension is set in such ...
Page 225 Cleaning, maintenance and inspection 7.5.10.8 Checking kickstand stability 1 Place the pedelec on a slight elevation of 5 cm. 2 Extend kickstand. 3 Jolt pedelec to check stability.  If pedelec topples over, tighten screws or change height of the kickstand. MY24H07 - 12_1.0_29.01.2024...
Page 226 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 227 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  1500 km after Maintenance 2 Every 100 hours ...
Page 228 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 229 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 230 Inspection and maintenance Perform major inspection 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 Fre- Components Description Criteria Measures if rejected quency Accept- Inspection...
Page 231 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.5 O.K. Dirt Cleaning month 6 months … Section 7.4.6 O.K. Untreated Stem 6 months Check mount fas- Section 7.5.5 …...
Page 232 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Wheel Before Concentricity Section 7.1.7 … O.K. Not straight Re-mount wheel each ride Wheel 6 months Assembly Section 7.5.1 … O.K. Loose Adjust quick release Once a Cleaning Section...
Page 233 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.12 O.K. Dirt Cleaning month Once a Care … Section 7.4.12 O.K. Untreated Treat month Hub gear 6 months Check mount fas- …...
Page 234 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 20 hours Refill oil … Section 7.4.19 O.K. No oil Refill oil 20 hours Clean wiper O.K. Dirt Cleaning EIGHTPINS 40 hours Clean slide bushing O.K.
Page 235 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Back-pedal 6 months Attachment Check mount … O.K. Loose Retighten screws brake braking fastening armature 6 months Attachment Check mount … O.K. Loose Retighten screws Brake system fastening...
Page 236 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months First examination See Section on … O.K. Error message Contact battery manu- Rechargeable Assembly facturer; take out of battery service, new battery 6 months Firmly in position, Check mount...
Page 237 Inspection and maintenance 8.5.1 Inspect frame 8.5.3 Inspecting and maintaining the 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 238 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 239 Inspection and maintenance 8.5.7 Inspecting the axle with quick  The quick release lever is flush with the lower release housing.  You should be able to see slight impression on the palm of your hand when you close the quick CAUTION release lever.
Page 240 Inspection and maintenance 8.5.8 Inspecting the fork 8.5.8.1 Inspecting 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 241 Inspection and maintenance 8.5.9 Inspecting the seat post 8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post Only applies to pedelecs with this equipment WARNING 1 Remove seat post from the frame. Intoxication from lubrication oil 2 Remove safety and protective cover. The lubrication oil for Eightpins seat posts is toxic 3 Clean seat post on the inside and outside.
Page 242 Inspection and maintenance 8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post Only applies to pedelecs with this equipment 1 Remove seat post from the frame. 2 Remove safety and protective cover. 3 Examine seat post rack for scratches, cracks and fractures.
Page 243 Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Preventing pain The pedelec is both a means of transport and a piece of sports equipment that 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.
Page 244 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 6.5.2). • Pain in the lower back •...
Page 245 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 246 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 247 Troubleshooting, fault clearance and repair BOSCH Smart System drive system More info on Intuvia 100 Description 14 If the drive system does not start The on-board computer indicates whether a Adjusting critical or less critical error has arisen in the drive after about 6 seconds, press the system.
Page 248 Troubleshooting, fault clearance and repair 9.2.2 Errors in assistance function Symptom Cause 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 249 Troubleshooting, fault clearance and repair 9.2.3 Battery errors Symptom Cause 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 250 Troubleshooting, fault clearance and repair Symptom Cause 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 251 Troubleshooting, fault clearance and repair 9.2.6 Correcting disc brake faults Symptom Cause Remedy Ringing and unusual  Contact specialist dealer. Fit a city or trekking tyre. sounds from disc brakes. Riding on asphalt with off-road tyres. Dirty or greasy brake disc. ...
Page 252 Troubleshooting, fault clearance and repair 9.2.7 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 253 Troubleshooting, fault clearance and repair 9.2.8 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 254 Troubleshooting, fault clearance and repair 9.2.9 Problems with hub gear Symptom Cause Remedy A noise is heard when the All gear speeds except 1. pedals are turning. A noise is heard when the pedelec is pushed All gear speeds except 1. backwards.
Page 255 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 256 Troubleshooting, fault clearance and repair 9.2.10 Correcting freewheel faults 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 257 Troubleshooting, fault clearance and repair 9.2.11 Correcting lighting faults Symptom Cause Remedy The front light or rear light The default settings in the electric drive Take pedelec out of service immediately. does not go on, even system have probably been configured when the switch is Contact specialist dealer.
Page 258 Troubleshooting, fault clearance and repair 9.2.14 Correcting other faults and 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.
Page 259 Troubleshooting, fault clearance and repair 9.2.15 Correcting faults in the SR SUNTOUR suspension fork 9.2.15.1 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 260 Troubleshooting, fault clearance and repair 9.2.15.2 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 261 Troubleshooting, fault clearance and repair 9.2.15.3 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 209: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
Page 262 Troubleshooting, fault clearance and repair 9.2.15.4 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 263 Troubleshooting, fault clearance and repair Repairs at the specialist dealer 9.3.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.3.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...
Page 264 Troubleshooting, fault clearance and repair 9.3.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 9.3.5 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 265 Troubleshooting, fault clearance and repair 9.3.7 Replacing pedelec components if lock function is installed 9.3.7.1 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 266 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 267 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 268 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 Kickstands Check mount fastening Functional check O.K. Loose Retighten screws Tyre pressure too low/ Tyres Tyre pressure check O.K.
Page 269 Documents Components Description Criteria Measures if rejected Assembly Accept- Tests Rejection /inspection ance Drive/gear shift Chain/cassette/ Refasten if necessary or replace Check for damage O.K. Damage sprocket/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...
Page 270 Documents 11.2 Inspection and maintenance log Diagnosis and documentation of current status Date: Frame number: Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Check mount Kickstands 6 months Functional check O.K.
Page 271 Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test 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 272 Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test 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; take out of service Check control panel Functional check...
Page 273 Documents Notes MY24H07 - 12_1.0_29.01.2024...
Page 274 Assembly 11.3 Parts list 11.3.1 FUTURA I-8 24-Q-0007, 24-Q-0008, 24-Q-0009 HE, TR, ZR Shape: HE; size: 53 cm Shape: HE; size: 57 cm Shape: HE; size: 61 cm Shape: TR; size: 45 cm Shape: TR; size: 49 cm Frames (variants) HAJJIE, Futura I-8 Shape: TR;...
Page 275 Assembly Pedal MARWI, SP828 Aluminium, with reflector, 9/16" Aluminium, crank set, crank length: 170 mm, for Crank set CAESAR, EC40-F9-BNI-170 BOSCH™ Gen3 motors Chain/belt KMC, e8 Chain, # links Chain guard HORN, Catena 17 Rear derailleur SHIMANO, ACERA RD-M3020-8 Sprocket/belt sprocket/ CAESAR EMS05-BHV03-S38T-C47 Freewheel, 38T freewheel...
Page 276 Assembly 11.3.2 FUTURA I-9 24-Q-0004, 24-Q-0005, 24-Q-0006 HE, TR, ZR Shape: HE, size: 53 cm Shape: HE, size: 57 cm Shape: HE, size: 61 cm Shape: TR, size: 45 cm Shape: TR, size: 49 cm Frames (variants) #, Futura I-9 Shape: TR, size: 53 cm Shape: ZR, size: 45 cm Shape: ZR, size: 49 cm...
Page 277 Assembly Aluminium, crank set, crank length: 170 mm; for Crank set FSA, CK-320/ISIS BOSCH™ Gen4 motors, ISIS Chain/belt SHIMANO, CN-LG500 Chain, # links Chain wheel/belt sprocket FSA, WB486/W0134 # Chain wheel: 38T/Spider Chain guard HORN, CATENA 18 Plastic, 38T Rear derailleur SHIMANO, CLARIS RD-R2000-GS Sprocket/belt sprocket/ SHIMANO, CUES CS-LG300-9 (11-46T)
Page 278 Assembly 11.3.3 LYON F7 24-Q-0019 HERCULES, LYON R7 coaster 700C Shape: ZR; frame height: 48 cm, aluminium Frames (variants) HERCULES, LYON R7 coaster 700C Shape: ZR; frame height: 52 cm, aluminium HERCULES, LYON R7 coaster 700C Shape: ZR; frame height: 56 cm, aluminium...
Page 279 Assembly On-board computer BOSCH, Purion 200 [BRC 3800] (EB13.200.03V) Charging current (max.): 2 A, 220-240 V; see Charger BOSCH, 2A Charger [BPC3200] (EB12.110.016) charger instructions Brake MAGURA, HS11 Rim brake Headlight FUXON, F16 EB 6-12V Rear light FUXON, R-232-EB 6...12 V Pannier rack, rear STANDWELL, Z-A23429/SW-ML001SF 700C MonkeyLoad system, with spring flap...
Page 280 Assembly 11.3.4 LYON R7 24-Q-0018 Shape: ZR; frame height: 48 cm, aluminium Frames (variants) HERCULES, LYON F7 non coaster 700C Shape: ZR; frame height: 52 cm, aluminium Shape: ZR; frame height: 56 cm, aluminium Tyres CST, Supero Optima Safe (C-3031) # Size: ETRTO 47-622 (28 ×...
Page 281 Assembly Charging current (max.): 2 A, 220-240 V; see Charger BOSCH, 2A Charger [BPC3200] (EB12.110.016) charger instructions # Length: 1000 mm | Hydraulic disc brake, # piston Front brake TEKTRO, # HD-T281 | Ø: 160 # Length: 2000 mm | Hydraulic disc brake, # piston Rear brake TEKTRO, # HD-T281 | Ø: 160...
Page 282 24-Q-0023 Shape: Wave; frame height: 45 cm, aluminium Frames (variants) HERCULES, NIZZA F7 NL DISC 700C Shape: Wave; frame height: 50 cm, aluminium Shape: Wave; frame height: 55 cm, aluminium # Size: ETRTO # «700 × 50C», 30 TPI, LDP: 3,...
Page 283 Assembly Shifter SHIMANO, NEXUS SL-C3000-7 Twist grip shifter with indicator, 7-speed Motor BOSCH, Active Line [BDU3320] (EB11.100.006) See Section 3.5.06.1 On-board computer BOSCH, Purion 200 [BRC 3800] (EB13.200.03V) Charging current (max.): 2 A, 220-240 V; see Charger BOSCH, 2A Charger [BPC3200] (EB12.110.016) charger instructions 3-finger brake lever | Length: 1000 mm | Hydraulic Front brake...
Page 284 Assembly 11.3.6 Prima E5 24-Q-7814 Frame Hercules Prima 5E 20" Size: 52 cm Tyres SCHWALBE, Supermoto-X Size: ETRTO 100-406, version: Performance Valve: AV; valve length: 40 mm; size: ETRTO 90/ Tube SCHWALBE, AV7/XXL 120- 406 mm Size: 20 mm × 622 mm; thickness: 0.30 mm,...
Page 285 Assembly 3-finger brake lever | Length: 1000 mm | Hydraulic Front brake TEKTRO, HD-T280 disc brake, 2-piston 3-finger brake lever | Length: 2000 mm | Hydraulic Rear brake TEKTRO, HD-T280 disc brake, 2-piston Brake disc TEKTRO, TR-35 Ø: 180 mm Headlight SATE LITE, C12 Rear light...
Page 286 Assembly 11.3.7 ROB FOLD F7 24-Y-0008 Shape: Gent; frame height: 50 cm, aluminium Frames (variants) HERCULES, ROB FOLD F7 20" Shape: Gent; frame height: 50 cm, aluminium Size: ETRTO 55-406 (20 × 2.15 inches), version: Tyres SCHWALBE, Big Ben RaceGuard Valve: AV;...
Page 287 Assembly On-board computer BOSCH, Purion 200 [BRC 3800] (EB13.200.03V) Charging current (max.): 2 A, 220-240 V; see Charger BOSCH, 2A Charger [BPC3200] (EB12.110.016) charger instructions 3-finger brake lever | Length: 1300 mm | Hydraulic Front brake TEKTRO, HD-T280 disc brake, 2-piston 3-finger brake lever | Length: 2000 mm | Hydraulic Rear brake TEKTRO, HD-T280...
Page 288 Assembly 11.3.8 ROB FOLD R8 24-Y-0007 Frame HERCULES, ROB FOLD R8 coaster 20" Shape: Gent; frame height: 50 cm, aluminium Size: ETRTO 55-406 (20 × 2.15 inches), version: Tyres SCHWALBE, Big Ben RaceGuard Valve: AV; valve length: 40 mm; size: ETRTO 40/ Tube SCHWALBE, AV7 (20")
Page 289 Assembly 3-finger brake lever | Length: 2000 mm | Hydraulic Rear brake TEKTRO, HD-T280 disc brake, 2-piston Brake disc TEKTRO, TR-35 Ø: 180 mm Brake disc TEKTRO, TR-47 Ø: 160 mm Headlight FUXON, FS-50 EB LED, 50 lx, 6… 12 V Rear light FUXON, RZ-100EB 6–12 V...
Page 290 Documents 11.4 Charger operating instructions MY24H07 - 12_1.0_29.01.2024...
Page 291 Documents 4A Charger MY24H07 - 12_1.0_29.01.2024...
Page 292 Documents MY24H07 - 12_1.0_29.01.2024...
Page 293 Documents MY24H07 - 12_1.0_29.01.2024...
Page 294 Documents MY24H07 - 12_1.0_29.01.2024...
Page 295 Documents MY24H07 - 12_1.0_29.01.2024...
Page 296 Documents MY24H07 - 12_1.0_29.01.2024...
Page 297 Glossary Glossary Bicycle for young adults Disc brake Source: ISO 4210-2: bicycle 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 298 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 299 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 300 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 Bluetooth Low Energy EPAC Electric power-assisted cycle...
Page 301 Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* HERCULES GmbH Janine Otto Longericher Strasse 2 c/o ZEG Zweirad-Einkaufs-Genossenschaft eG 50739 Köln Longericher Strasse 2 Germany 50739 Köln Germany The machine, pedelec types: 24-Q-0004...
Page 302 EN 62133-2:2017-11 Secondary cells and batteries containing alkaline or other non-acid electrolytes. Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications – Part 2: Lithium systems. Cologne, 21.09.2023 ……………………………………………………………………………………………… Georg Honkomp, Managing Director, HERCULES GmbH MY24H07 - 12_1.0_29.01.2024...
Page 303 Appendix Directive declaration of conformity with RED Directive LED Remote Robert Bosch GmbH, Bosch eBike Systems, hereby declares that the LED Remote radio system type complies with Directive 2014/53/EU. The complete EU declaration of conformity is available online at: https://www.bosch-ebike.com/conformity Purion 200 Robert Bosch GmbH, Bosch eBike Systems, hereby declares that the Kiox 300 radio system complies with Directive 2014/53/EU.
Page 304 Appendix III. CE Declaration of Conformity eBike Systems eBike Systems EU Declaration of Conformity Robert Bosch GmbH Robert Bosch GmbH 72757 Reutlingen 72757 Reutlingen Apparatus model / product GERMANY GERMANY www.bosch.com www.bosch.com Part number(s): EB13100003 Model number(s): BHU3600 Name and address of the manufacturer Robert Bosch GmbH 72757 Reutlingen GERMANY...
Page 305 Appendix eBike Systems eBike Systems Annex [en | de | fr | es | pt | it | nl | da | sv | fi | is | el | pl | cs | sk | hu | ro | bg | sl | hr | et | lv | It] 0.
Page 306 Appendix eBike Systems eBike Systems EU Declaration of Conformity Apparatus model / product Robert Bosch GmbH Robert Bosch GmbH Part number(s): 72757 Reutlingen 72757 Reutlingen x BBP3770, BBP3771, BBP3760, BBP3761, BBP3750, BBP3751 GERMANY GERMANY x BBP3540, BBP3551, BBP3570, BBP3580 www.bosch.com www.bosch.com x BBP3242, BBP3241, BBP3240 x BBP3350, BBP3340...
Page 307 Keyword index Keyword index Brake calliper, 50 Cargo bike, 297 position, 50 Cassette, Activity tracking, torque, 82 - clean, 203 - activate 157 Brake disc, 50 CE marking, 297 Air valve, 38 - check, 216 Chain guard 21 position, 38 - clean 203 Chain guard, App,...
Page 308 Keyword index Disc brake, 297 French valve, see Presta valve - service 228 torque, 83 Front derailleur, position, 45 Display, - clean, 203 torque, 87 - insert, 159 torque, 91 Hydraulic brake system, Drive belt, 297 Front light, 58 - check 215 Drive system, 57 Front wheel brake, 51 Hydraulic lockout 70...
Page 309 Keyword index Minimum insertion depth - inspect, 237 -adjust sag, 147 marking, 121 - use, 169 Rear light, 58 Minimum insertion depth, 298 Parts list, 301 - clean 199 Minus button, 62 Patent seat post, 54 Rear wheel brake, 50, 51 Model year, 298 Pedal, 51 Rebound adjuster, 38...
Page 310 Keyword index - inspect, 241 Winter break, see Break in - maintain, 207 operation Time format, - patent seat post 54 Work environment, 300 - set, 161 - suspension seat post 54 Total deflection 299 remote control torque, 83 Trailer, 164 Year of manufacture, 300 torque, 84 Transportation, 93...

Hercules BOSCH KIOX 300 INTUVIA 100 Translation Of Original Operating Instructions

About These Operating Instructions

Safety

Description

Transporting and Storing

Assembly 5.1 Unpacking

Operation

Quick Links

Need help?

Questions and answers

Related Manuals for Hercules BOSCH KIOX 300 INTUVIA 100

Summary of Contents for Hercules BOSCH KIOX 300 INTUVIA 100

Table of Contents