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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE
Translation of original operating instructions for
HERCULES MTB pedelecs with SHIMANO drive
SHIMANO, SC-E5003
23-R-0002
NOS FS 2.2
23-R-0005
NOS 2.1
23-R-0006
NOS 2.1
24-Q-0078
NOS SUV 2.3
24-Q-0079
NOS SUV 2.3
24-R-0006
NOS FS 2.2
SHIMANO, SC-E6000
23-Q-0039
NOS FS SUV 2.1
23-Q-0040
NOS FS SUV 2.2
23-Q-0041
NOS SUV 2.1
23-Q-0042
NOS SUV 2.1
23-Q-0043
NOS SUV 2.1
23-Q-0044
NOS SUV 2.2
23-Q-0045
NOS SUV 2.2
23-Q-0046
NOS SUV 2.2
SHIMANO, SC-EM800
23-R-0001
NOS FS 2.1
M Y 2 4 H M 2 - 1 2 _ 1 . 0 _ 3 0 . 0 1 . 2 0 2 4

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Summary of Contents for Hercules SHIMANO SC-E5003

  • Page 1 IMPORTANT READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for HERCULES MTB pedelecs with SHIMANO drive SHIMANO, SC-E5003 23-R-0002 NOS FS 2.2 23-R-0005 NOS 2.1 23-R-0006 NOS 2.1 24-Q-0078 NOS SUV 2.3...
  • Page 2: Table Of Contents

    Contents Contents About these operating instructions Manufacturer Laws, standards and directives Language 1.3.1 Warnings 1.3.2 Markups For your information 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 Saddle 3.4.6 Seat post 3.4.7 Mechanical drive system 3.4.8 SHIMANO electric drive system 3.4.9 SIMPLON battery 3.4.10 Handlebars with SHIMANO SC-E5003 on-board computer 3.4.11 On-board computer 3.4.12 On-board computer 3.4.13 Warnings and errors 3.4.14 Handlebars with SHIMANO SC-EM800 3.4.15 On-board computer 3.4.16...
  • Page 4 Contents Instruction and customer service Adjusting the pedelec 6.4.1 Preparing 6.4.2 Riding position 6.4.3 Seat post 6.4.4 Saddle 6.4.5 Handlebars 6.4.6 Stem 6.4.7 Handles 6.4.8 Tyres 6.4.9 Brake 6.4.10 Control panel and gear shift 6.4.11 Suspension and damping 6.4.12 Adjusting the suspension fork sag 6.4.13 Adjusting the rear frame damper sag 6.4.14...
  • Page 5 Contents 6.18.4 Changing the displayed journey data 6.18.5 Resetting the trip distance (DST) 6.18.6 Setting the indicator units 6.18.7 Setting the start gear 6.19 Using the on-board computer 6.19.1 Using the riding light 6.19.2 Using the push assist system 6.19.3 Switching the journey information 6.20 Using the on-board computer...
  • Page 6 Contents 7.3.10 Cleaning the tyres 7.3.11 Cleaning the spokes and spoke nipples 7.3.12 Cleaning the hub 7.3.13 Cleaning the switching elements 7.3.14 Cleaning the SRAM AXS rear derailleur 7.3.15 Cleaning the cassette, chain wheels and front derailleur 7.3.16 Cleaning the brake 7.3.17 Cleaning the brake disc 7.3.18...
  • Page 7 Contents Troubleshooting, fault clearance and repair Preventing pain 9.1.1 Sitting discomfort 9.1.2 Pain in hips 9.1.3 Backache 9.1.4 Pain in shoulders and nape of neck 9.1.5 Numb or aching hands 9.1.6 Pain in upper thigh 9.1.7 Knee pain 9.1.8 Pain in the foot SHIMANO 5003 drive system troubleshooting 9.2.1 The drive system or display do not start up...
  • Page 8 Contents Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity RED Declaration of Conformity III. Declaration of Conformity for incomplete machine Keyword index MY24HM2 - 12_1.0_30.01.2024...
  • Page 9 About these operating instructions Thank you for your trust! Copyright HERCULES all-terrain pedelecs are premium- © HERCULES GmbH quality sports equipment. You have made an excellent choice. Your specialist dealer will Distribution or reproduction of these operating provide you with guidance and instruction and instructions and utilisation or communication of assemble your product.
  • Page 10: About These Operating Instructions

    About these operating instructions About these operating instructions Manufacturer 1.3.1 Warnings Warnings indicate hazardous situations and actions. HERCULES GmbH You will find three categories of warnings in the Longericher Strasse 2 50739 Köln operating instructions: Germany WARNING Tel.: +49 4473 92617 0...
  • Page 11: For Your Information

    About these operating instructions For your information Sections intended for technical staff are highlighted in blue and marked with a spanner Different icons are used to make things easier to symbol. Technical staff are trained bicycle read. mechanics, bicycle mechatronics engineers or similar.
  • Page 12: 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 of stamped on it (see Figure 2). The frame number pedelecs with the type numbers: can be used to link the pedelec with the owner. Type no.
  • Page 13: 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 14 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 15: 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 8.5.10.
  • Page 16: 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 17: Toxic Substances

    Safety Toxic substances 2.2.2 Toxic substances If substances are released or used which pose a risk to people and the environment, effective protective measures must be taken. Toxic substances (also known as poison or toxins) refer to substances which can cause damage to Possible hazards, contamination and health living beings if they enter the organism above a hazards due to:...
  • Page 18: Requirements For The Pedelec Rider

    Safety Personal protective equipment Defective battery Liquids and vapours may leak from damaged or  Wear a suitable helmet. The helmet must have faulty batteries. Excessively high temperatures a reflective strip or a light in a clearly visible may also cause liquids and vapours to leak from colour.
  • Page 19: Safety Markings And Safety Instructions

    Safety Safety markings and safety What to do in an emergency instructions 2.8.1 Dangerous situation in road traffic Pedelec and battery nameplates contain the following safety markings and safety instructions:  If you encounter any hazards or dangers in road traffic, apply the brake until the pedelec comes to a halt.
  • Page 20: Battery Vapour Emission

    Safety After contact with eyes After skin contact 1 Rinse eyes under flowing water for at least ten 1 Remove any solid particles immediately. minutes with the lids open; also rinse under 2 Remove contaminated clothing immediately. lids. 3 Rinse the affected area with plenty of water for 2 Immediately consult a doctor in case of any at least 15 minutes.
  • Page 21: Toxic Substances

    Safety Toxic substances 2.9.2 Toxic materials If substances are released or used which pose a risk to people and the environment, effective protective measures must be taken. Toxic substances (also known as poison or toxins) refer to substances which can cause damage to Possible hazards, contamination and health living beings if they enter the organism above a hazards due to:...
  • Page 22: Requirements For The Pedelec Rider

    Safety 2.11 Vulnerable groups Defective battery Liquids and vapours may leak from damaged or  Keep batteries and the charger away from faulty batteries. Excessively high temperatures children and people with reduced physical, may also cause liquids and vapours to leak from sensory or mental capacities or lacking in the battery.
  • Page 23: Safety Markings And Safety Instructions

    Safety 2.14 Safety markings and safety 2.15 What to do in an emergency instructions 2.15.1 Dangerous situation in road traffic Pedelec and battery nameplates contain the following safety markings and safety instructions:  If you encounter any hazards or dangers in road traffic, apply the brake (emergency stop system) until the pedelec comes to a halt.
  • Page 24: Battery Vapour Emission

    Safety After contact with eyes After skin contact 1 Rinse eyes under flowing water for at least ten 1 Remove any solid particles immediately. minutes with the lids open; also rinse under 2 Remove contaminated clothing immediately. lids. 3 Rinse the affected area with plenty of water for 2 Immediately consult a doctor in case of any at least 15 minutes.
  • Page 25: Description

    Description Description Proper use All checklists and instructions for actions in these regulations for the prevention of accidents and operating instructions met. Approved accessories environmental protection in the respective country can be installed by specialist staff. of use must be adhered to. Use the pedelec when it is in perfect, proper The rechargeable batteries are designed to working order only.
  • Page 26: Area Of Use As Per En 17406, From Model Year 2024

    Description 3.1.2 Area of use as per EN 17406, from model year 2024 Average Area of use Unsuitability speed [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 27 Description 3.1.2.1 Up to model year 2023 Area of use Unsuitable terrain Suitable for tarmacked and paved roads. Never ride off road or perform jumps. Suitable for tarmacked roads, cycle paths, firm gravel Never ride off road or perform jumps over 15 cm. tracks and longer sections with moderate slopes and jumps up to 15 cm.
  • Page 28: Technical Data For Entire Vehicle

    Description Technical data for entire vehicle 3.2.1 Shimano Power output/system 250 W (0.25 kW) Shut-off speed 25 km/h Charging temperature 0 °C … +45 °C Operating temperature -20 °C … +45 °C Storage temperature +10 °C … +50 °C Work environment temperature +15 °C …...
  • Page 29: Maximum Permitted Total Weight (Ptw)

    Description 3.2.2 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 30: Environmental Requirements

    Description 3.2.3 Environmental requirements 3.2.3.1 SHIMANO Temperatures under -10 °C and over +60 °C must be avoided. You can be ride the pedelec within a temperature You must also keep within the following range between -10 °C and +50 °C. The electric temperature ranges: drive system is limited in its performance outside this temperature range.
  • 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: Model Year 23 Nameplate

    EN 15194 0,25 kW / 25 km/h zGG 150 kg EPAC 25 kg BJ 2022 / MJ 2023 Figure 3: 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 33: Components

    Description Components 3.4.1 Overview of city and trekking bicycle 21 22 23 24 Figure 4: Pedelec viewed from right, example Wheel Rear frame damper Seat post Chain Suspension fork Saddle Chain guard Guard Pannier rack Pedal crank Steering headset Rear light Motor Front light Reflector...
  • Page 34 Description 3.4.1.1 Components and repair parts for NOS FS 2.1 23-R-0001 Diamant Shape: Diamant; size: 41 cm Shape: Diamant; size: 44 cm Frame SUNRISE, R13/21 Shape: Diamant; size: 47 cm Shape: Diamant; size: 50 cm Rear frame damper ROCKSHOX, Deluxe Select (RS-DLX-SEL) Installation length: 210 mm ×...
  • Page 35 Description Rear derailleur SHIMANO, DEORE XT RD-M8100-SGS See Section # Sprocket/belt sprocket/ Cassette, 12-speed, 10-12-14-16-18-21-24-28-33- SHIMANO, DEORE CS-M6100-12 (10-51T) freewheel 39-45-51T (10-51T); see Section # Shifter SHIMANO, DEORE SL-M6100-IR Shifter with indicator, 12-speed Motor SHIMANO, DU-EP800 See Section 3.5.06.1 On-board computer SHIMANO, SC-EM800 See Section 3.5.2 SHIMANO, SW-300...
  • Page 36 Description 3.4.1.2 Components and repair parts for NOS FS 2.2 23-R-0002 Diamant, Trapez, Wave Shape: Diamant; size: 41 cm Shape: Diamant; size: 44 cm Frame SUNRISE, R13/21 Shape: Diamant; size: 47 cm Shape: Diamant; size: 50 cm Rear frame damper ROCKSHOX, Deluxe Select (RS-DLX-SEL) Installation length: 210 mm ×...
  • Page 37 Description Ø: 30.9 mm; deflection: 100 mm/length: 200 mm Ø: 30.6 mm; deflection: 125 mm/length: 200 mm Seat post LIMOTEC, A1/RM-04 Ø: 30.6 mm; deflection: 150 mm/length: 200 mm Ø: 30.6 mm; deflection: 170 mm/length: 200 mm Saddle clamp KALLOYUNO, SC-ML1 Ø: 34.9 mm Pedal VP COMPONENTS, VP-469...
  • Page 38 Description 3.4.1.3 Components and repair parts for 24 NOS FS 2.1 23-R-0006 Diamant SUNRISE, Frame R14RAW Shape: Diamant; size: 41 cm Shape: Diamant; size: 44 cm Shape: Diamant; size: 48 cm Frame Shape: Diamant; size: 52 cm Shape: Trapez; size: 44 cm Shape: Trapez;...
  • Page 39 Description Chain wheel/belt sprocket Chain wheel/belt sprocket FSA, W0164 # Spider; see Section # Chain wheel/belt sprocket FSA, WB496 # Chain wheel, 38T; see Section # Chain wheel/belt sprocket FSA, WB496 # Chain wheel, 38T; see Section # Chain guard MR CONTROL, CH-E8-MINI …...
  • Page 40 Description 3.4.1.4 Components and repair parts for NOS 2.1 23-R-0005 Diamant SUNRISE, Frame R14RAW Shape: Diamant; size: 41 cm Shape: Diamant; size: 44 cm Shape: Diamant; size: 48 cm Frame Shape: Diamant; size: 52 cm Shape: Trapez; size: 44 cm Shape: Trapez;...
  • Page 41 Description Chain/belt SHIMANO, CN-HG541 # Chain, # links; see Section # FSA, W0164 # Spider; see Section # Chain wheel/belt sprocket FSA, WB496 # Chain wheel, 38T; see Section # Chain guard MR CONTROL, CH-E8-MINI … Rear derailleur SHIMANO, DEORE RD-M5120-SGS See Section # Sprocket/belt sprocket/ SUNRISE, CSMS2.TAZ0.ES0...
  • Page 42 Description 3.4.1.5 Components and repair parts for NOS FS SUV 2.1 23-Q-0039 Diamant Shape: Diamant; size: 41 Shape: Diamant; size: 44 Frame SUNNY FRM R13/24 NOS FS SUV Shape: Diamant; size: 47 Shape: Diamant; size: 50 Rear frame damper SR SUNTOUR, Edge Plus 2CR 210 x 55 Tyres SCHWALBE, Smart Sam...
  • Page 43 Description Rear derailleur SHIMANO, DEORE XT RD-M8100-SGS See Section # Sprocket/belt sprocket/ Cassette, 12-speed, 10-12-14-16-18-21-24-28-33- SHIMANO, DEORE CS-M6100-12 (10-51T) freewheel 39-45-51T (10-51T); see Section # Shifter SHIMANO, DEORE XT SL-M8100-R Shifter with indicator, 12-speed Motor SHIMANO, DU-EP600 See Section 3.5.06.1 On-board computer SHIMANO, SC-E6100 See Section 3.5.2...
  • Page 44 Description 3.4.1.6 Components and repair parts for NOS FS SUV 2.2 23-Q-0040 Diamant SUNNY FRM R13/24 NOS FS SUV Shape: Diamant; size: 41 Shape: Diamant; size: 44 Frame Shape: Diamant; size: 47 Shape: Diamant; size: 50 Rear frame damper SR SUNTOUR, Edge Plus 2CR 210 x 55 Tyres SCHWALBE, Smart Sam...
  • Page 45 Description Rear derailleur SHIMANO, DEORE XT RD-M8100-SGS See Section # Sprocket/belt sprocket/ SHIMANO, DEORE CS-M6100-12 (10-51T) Cassette, 12-speed, 10-12-14-16-18-21-24-28-33- freewheel 39-45-51T (10-51T); see Section # Shifter SHIMANO, DEORE XT SL-M8100-R Shifter with indicator, 12-speed Motor SHIMANO, DU-EP600 See Section 3.5.06.1 On-board computer SHIMANO, SC-E6100 See Section 3.5.2...
  • Page 46 Description 3.4.1.7 Components and repair parts for NOS SUV 2.1 23-Q-0041, 23-Q-0042, 23-Q-0043 Diamant, Trapez, Wave Shape: Wave; size: 41 cm Shape: Wave; size: 44 cm Frame SUNRISE, R14RAW Shape: Wave; size: 48 cm Shape: Wave; size: 52 cm Size: ETRTO 65-584 (27.5 × 2.60 inches), version: Tyres SCHWALBE, Johnny Watts DD, RaceGuard;...
  • Page 47 Description FSA, W0164 # Spider; see Section # FSA, W1155 # Chain guard: 36-38T; see Section # Chain wheel/belt sprocket FSA, WB496 # Chain wheel, 38T; see Section # FSA, WB496/W0164 # Chain wheel: 38T/Spider; see Section # Rear derailleur SHIMANO, SLX RD-M7100-SGS See Section # Sprocket/belt sprocket/...
  • Page 48 Description 3.4.1.8 Components and repair parts for NOS SUV 2.2 23-Q-0044, 23-Q-0045, 23-Q-0046 Diamant, Trapez, Wave Shape: Wave; size: 41 cm Shape: Wave; size: 44 cm Shape: Wave; size: 48 cm Shape: Wave; size: 52 cm Shape: Diamant; size: 41 cm Frame SUNRISE, Frame R14RAW Shape: Diamant;...
  • Page 49 Description Saddle clamp KALLOYUNO, XC68C Ø: 34.9 mm Pedal VP COMPONENTS, VP-469 Crank set SAMOX, ET40-F17-SHP80 Pedal crank length: 170 mm Chain/belt SHIMANO, CN-HG541 # Chain, 120 links; see Section # FSA, W0164 # Spider; see Section # Chain wheel/belt sprocket FSA, W1155 # Chain guard: 36-38T;...
  • Page 50 Description 3.4.1.9 Components and repair parts for NOS SUV 2.3 24-Q-0078, 24-Q-0079 Diamant, Trapez Shape: Diamant; size: 41 cm Shape: Diamant; size: 44 cm Shape: Diamant; size: 48 cm Frame SUNRISE, Frame R14RAW Shape: Diamant; size: 52 cm Shape: Trapez; size: 44 cm Shape: Trapez;...
  • Page 51 Description Chain/belt SHIMANO, CN-HG541 # Chain, # links; see Section # FSA, W0164 # Spider; see Section # Chain wheel/belt sprocket FSA, WB496 # Chain wheel, 38T; see Section # Chain guard MR CONTROL, CH-E8-MINI … Rear derailleur SHIMANO, DEORE RD-M5120-SGS See Section # Sprocket/belt sprocket/ SUNRISE, CSMS2.TAZ0.ES0...
  • Page 52: Chassis

    Description 3.4.2 Chassis Carbon frame The chassis comprises two components: Carbon (CFRP) is a carbon-fibre-reinforced polymer made of high-strength, rigid fibres. • Frame and Carbon frames comprise several layers of carbon • steering system with an epoxy resin matrix. The uppermost layer is known as the visible layer.
  • Page 53 Description Rider’s height [cm] Frame size [cm] Rider’s height [cm] Frame size [cm] 155… 165 160… 175 43… 48 46… 48 165… 175 48… 53 165… 180 49… 51 175… 185 53… 58 170… 185 52… 54 185… 195 58… 62 175…...
  • Page 54 Description 3.4.2.2 Rear frame damper A rear frame damper is primarily fitted to mountain bikes and helps to protect the pedelec and rider against impacts and vibrations caused by uneven ground. Rear frame damper suspension A rear frame damper deflects when a steel spring, it stays in contact with the ground instead air suspension, or both suspension types act on it.
  • Page 55 Description Rear frame damper damping After compressing, the suspension fork returns to A distinction is made between two types of its original position. If there is a damper, it will dampers: decelerate movement, preventing the suspension • Rebound dampers, system from springing back in an uncontrolled •...
  • Page 56 Description Compression damper The compression damper controls the When optimally adjusted, the rear frame damper compression lifting speed or amount by which the counteracts deflection, stays higher in its rear frame damper deflects in response to slow deflection range and helps to maintain speed impacts.
  • Page 57 Description Structure of ROCKSHOX Deluxe Select Figure 9: ROCKSHOX Deluxe Select rear frame damper structure design Rebound adjuster (rear frame damper) Air valve (rear frame damper) Scale O-ring MY24HM2 - 12_1.0_30.01.2024...
  • Page 58 Description Structure of SR SUNTOUR Edge Plus 2CR Figure 10: SUNTOUR Edge Plus 2CR rear frame damper structure Air reservoir Compression lever (rear frame damper) Rebound adjuster (rear frame damper) Air valve (rear frame damper) Overall length Damper unit O-ring MY24HM2 - 12_1.0_30.01.2024...
  • Page 59 Description 3.4.2.3 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.4.2.4 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
  • Page 60 Description 3.4.2.6 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 14: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
  • Page 61 Description Parts of a suspension fork Figure 15: 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 62 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 17: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
  • Page 63 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 64 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 65 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 66 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 67 Description 3.4.2.8 SR SUNTOUR 3CR-PCS The Suntour 3CR-PCS cartridge features a PCS damper platform with • a low-speed compression damper • a rebound damper Floating pistons within the PCS cartridge provide consistent damping on all driving surfaces through minimal cavitation (formation and dissolution of bubbles by mixing air and oil).
  • Page 68 Description 3.4.2.9 SR SUNTOUR 2CR-PCS The Suntour 3CR-PCS cartridge features a PCS damper platform with • a low-speed compression damper • a rebound damper Floating pistons within the PCS cartridge provide consistent damping on all driving surfaces through minimal cavitation (formation and dissolution of bubbles by mixing air and oil).
  • Page 69 Description 3.4.2.10 SR SUNTOUR cartridge LOR The SR Suntour LOR cartridge features • a low-speed compression damper 2. 2. • a low-speed rebound damper Before riding, use the rebound adjuster (suspension fork) (1) to adjust the system to the surface you will ride on. The suspension system can be adjusted to the current surface during rides using the low-speed compression adjustment wheel (2).
  • Page 70 Description Structure of ROCKSHOX DebonAir™ cartridge The air valve (fork) is located at the top of the DebonAir™ cartridge. Figure 28: DebonAir air valve (fork) MY24HM2 - 12_1.0_30.01.2024...
  • Page 71: Wheel

    Description 3.4.3 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 72 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 73 Description Bead core 3.4.3.3 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 74 Description Presta valve 3.4.3.6 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 75 Description 3.4.3.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.
  • Page 76: Brake

    Description 3.4.4 Brake 3.4.4.2 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 77 Description 3.4.4.3 Disc brake Figure 40: 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 78: Saddle

    Description 3.4.5 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 79 Description 3.4.5.1 Ladies’ saddle 3.4.5.2 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 80: Seat Post

    Description 3.4.6 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 81 Description 3.4.6.3 Structure of LIMOTEC, A1 The LIMOTEC A1 seat post is a continuously height-adjustable seat post. The remote control on the handlebars lowers the seat post. This can be used to adjust the saddle height during a ride, e.g. when stopped at traffic lights.
  • Page 82: Mechanical Drive System

    Description 3.4.7 Mechanical drive system 3.4.7.1 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 83: Shimano Electric Drive System

    Overview 3.4.8 SHIMANO electric drive system Bluetooth® LE connection The pedelec has an electric drive system in All information shown on the on-board computer addition to a mechanical one. can be sent to external devices which support Bluetooth® LE connections. 3.4.8.1 SC-E5003 E-TUBE PROJECT for smartphones and/or tablets can be used if a Bluetooth®...
  • Page 84 Overview 3.4.8.3 SC-EM800, SC-EN600, SC-EN610 3.4.8.4 Motor As soon as the muscle power required for pedalling passes a certain level, the motor is activated gently and assists the pedalling motion. The motor force is determined by the set level of assistance.
  • Page 85: Simplon Battery

    Overview 3.4.9 SIMPLON battery The lithium ion battery has an interior electronic protection circuit, which is specifically designed for the charger and the pedelec. The battery temperature is monitored at all times. The battery is protected against deep discharge, overcharging, overheating and short circuit. In the event of a hazard, a protective circuit switches the battery off automatically.
  • Page 86 The drive system is operated using the on-board computer. The drive system is 3 buttons on the on-board computer. operated using 4 buttons. Figure 56: SHIMANO SC-E5003 on-board computer Up button Figure 58: SHIMANO SC-E6100 Select button Down button...
  • Page 87 Description 3.4.9.5 Control panel The electric drive system is operated using the on- board computer (II) and the left-hand control panel (I). The right-hand control panel (III) switches the gears. Figure 63: 2-switch control panel MTB switch control panel Figure 60: Overview of control panel position •...
  • Page 88: Handlebars With Shimano Sc-E5003 On-Board Computer

    Description 3.4.10 Handlebars with SHIMANO SC-E5003 on-board computer Figure 65: Detailed view of handlebars with SHIMANO SC-E5003 on-board computer, used as example Rear wheel hand brake Handles Bell Main beam switch Headlight Switch On-board computer Shifter Front wheel handbrake MY24HM2 - 12_1.0_30.01.2024...
  • Page 89: On-Board Computer

    Total kilometres Table 228: Journey data 3.4.11.2 Fully Automatic indicator Only applies to pedelecs with this equipment Figure 66: SHIMANO SC-E5003 on-board computer An electronic gear shift offers the choice between automatic and manual gear switching. The Up button Select button...
  • Page 90 Description 3.4.11.4 Maintenance indicator Indicates that maintenance is required (see Section 9.7.3). 3.4.11.5 Push assist indicator This symbol is displayed if the pedelec is switched to push assist mode. 3.4.11.6 Level of assistance indicator Indicates the current level of assistance. The greater the level assistance is, the longer the indicator bar is.
  • Page 91 Description 3.4.11.10SHIMANO SC-EN500 on-board 3.4.11.11Journey Data indicator computer Four different types of journey data can be displayed. The pedelec is operated using five buttons on the on-board computer. Display Function GEAR Current selected gear (only visible with electronic gear shift). RANGE Range for the selected level of assistance.
  • Page 92 Description 3.4.11.14Maintenance indicator Indicates that maintenance is required (see Section 6.3.3). 3.4.11.15Push assist indicator This symbol is displayed if the pedelec is switched to push assist mode. 3.4.11.16Level of assistance indicator Indicates the current level of assistance. The greater the level assistance is, the longer the indicator bar is.
  • Page 93: On-Board Computer

    Operation 3.4.12 On-board computer The on-board computer has a light button (1), a display screen (2), a function button (3) and an on- off button (4). Figure 71: On-screen indicators overview 1 Speed unit of measure indicator A selection can be made in the system settings to determine whether the speed is displayed in kilometres per hour [km/h] or miles per hour [mph].
  • Page 94 Operation 4 Bluetooth indicator Journey information Displayed when an external device is connected The displayed journey information can be via Bluetooth® LE. switched. The current selected journey information is displayed on the display screen. 5 Light indicator The following can be selected: The light symbol is shown when the light is on.
  • Page 95: Warnings And Errors

    Operation 3.4.13 Warnings and errors Default settings The drive system monitors itself continuously and Display Function if an error is detected, it is indicated by a system message. The system may switch off BAC KLI GHT automatically depending on the type of error. You BRI GHT N ESS will find more information and a table containing BEEP...
  • Page 96: Handlebars With Shimano Sc-Em800

    Description 3.4.14 Handlebars with SHIMANO SC- EM800 5 67 Figure 72: Detailed view of handlebars with SHIMANO SC-E800 on-board computer, used as example Rear wheel hand brake Air valve Front wheel handbrake Lock out Handle On-board computer Control panel Shifter MY24HM2 - 12_1.0_30.01.2024...
  • Page 97: On-Board Computer

    Operation 3.4.15 On-board computer 3.4.15.1 Main screen After starting up, the main display screen The on-board computer has one button (1) and a appears. The main display screen has eight display screen (2). displays: Figure 73: SC-EM800 on-board computer details Figure 74: Overview of main display screen Function Shift mode indicator...
  • Page 98 Operation 4. Maintenance indicator 7. Current level of assistance indicator Indicates that maintenance is required. The selected level of assistance differs depending on the pedelec. The higher the selected level of  Contact your specialist dealer. assistance, the more the drive system assists with pedalling.
  • Page 99: Warnings And Errors

    Operation 3.4.16 Warnings and errors The drive system monitors itself continuously and if an error is detected, it is indicated by a system message. The system may switch off automatically depending on the type of error. You will find more information and a table containing all system messages in Section 6.3.
  • Page 100: Handbrake

    Description 3.4.17 Handbrake There is a handbrake on the left and right of the handlebars. Figure 75: 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 101: Shimano Gear Shift

    Description 3.4.18 SHIMANO gear shift 3.4.18.3 MTB switch control panel There is either a switch control panel or a shifter on the right side of the handlebars. There can be three different switches, depending on the model: • 3-switch control panel •...
  • Page 102 Description 3.4.18.6 Shifter SL-M8100 Figure 80: Shifter SL-M8100 Shifter Attachment screw for shifter MY24HM2 - 12_1.0_30.01.2024...
  • Page 103: Suspension And Damping

    Description 3.4.19 Suspension and damping 3.4.19.1 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 104 Description 3.4.19.2 SR SUNTOUR adjuster damper Only applies to vehicles with this equipment R2C2-PCS 3CR-PCS 2CR-PCS RC-PCS Model RC2-PCS Suspension fork Aion Durolux Mobie34 Mobie35 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with high-speed and low-speed setting options and high-/low-speed compression damper in the R2C2-PCS piston compensator system Rebound damper with low-speed setting option and high-/low-speed compression damper in the piston...
  • Page 105 Description LORC-PCS Model LORC Suspension fork Aion Axon Mobie25 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with low-speed setting option and low-speed compression damper with lockout in the piston LORC-PCS compensator system LORC Rebound damper with low-speed setting option and low-speed compression damper with lockout Rebound damper with low-speed setting option with lockout MY24HM2 - 12_1.0_30.01.2024...
  • Page 106 Description 3.4.19.3 SR SUNTOUR adjuster damper with remote control Only applies to vehicles with this equipment There is a remote control to open and close the damper on the handlebars. R-3CR-PCS RLRC-PCS RLRC Model R-2CR-PCS Suspension fork Aion Axon Mobie25 Mobie34 Raidon Zeron35...
  • Page 107: Suspension And Damping On Rear Frame Damper

    Description 3.4.20 Suspension and damping on rear frame damper Only applies to vehicles with this equipment 3.4.20.1 SR SUNTOUR Explanation Compression lever Blue operating element Rebound adjuster Red operating element Model Three rebound adjuster Two rebound adjuster Low-speed compression Low-speed rebound positions positions lever and low-speed rebound...
  • Page 108 Description Model R-3CR R-2CR RLR/RLR8 LOR/LOR8 Remote lock with three Remote lock with two RLR: LOR: Low-speed rebound rebound adjuster positions: rebound adjuster positions: Remote lock with rebound damper with two • lock • lock adjuster compression lever RLR8 positions: •...
  • Page 109: Battery Level Indicator

    Description 3.4.21 Battery level indicator 3.4.21.1 Checking the battery charge level Charge level indicator with five LEDs Each LED represents about 20% of charge.  Press the On-Off button (battery). LED 1, 2, 3, 4, 5 Battery level  The LEDs will light up and go out again after 5 seconds.
  • Page 110: Transporting And Storing

    Transporting and storing Transporting and storing Transportation 4.1.2 Transporting the pedelec Lithium-ion batteries store great amounts of energy. You must comply with a few precautionary CAUTION measures when transporting gas cylinders.  Discharge the battery to about 30% before Crash caused by unintentional activation placing pedelec in a vehicle to transport or take There is a risk of injury if the electric drive system it on a trip.
  • Page 111: Shipping A Pedelec

    Transporting and storing 4.1.3 Shipping a pedelec 4.1.2.3 By local transport You can normally take pedelecs on local public  Private users are not permitted to ship transport, e.g. by bus or suburban rail, if you rechargeable batteries, neither by road not by purchase a bike ticket.
  • Page 112: Storing

    Transporting and storing Storing  Remove the on-board computer from its mount  Store pedelec, on-board computer, battery and if the pedelec is not going to be used for up to charger in a clean, dry place where they are four weeks.
  • Page 113: 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 114: 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 115: 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 116: Adjusting The Limotec Seat Post

    Assembly 5.3.3 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 117: Preparing The Wheel

    Assembly 5.3.4 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 118: Installing The Wheel In The Suntour Fork

    Assembly 5.3.5 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.5.1 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 119 Assembly 5.3.5.2 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 120 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 97: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
  • Page 121 Assembly 5.3.5.3 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 122: 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 123: 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 124: 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 125 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 126: 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 127: Instruction And Customer Service

    Operation Instruction and customer service 6.4.1 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 128: Riding Position

    Operation 6.4.2 Riding position The starting point for a comfortable posture is the The pelvis is positioned incorrectly if it tilts slightly correct position of the pelvis. If the pelvis is in the backwards. As a result, the spine becomes curved wrong position, it can cause different types of and can no longer deflect to an optimal extent.
  • Page 129 Operation Position on roadster Position on city bike Position on trekking Position on sports bike bike Upright, almost vertical Slightly inclined upper Sharply inclined upper Greatly inclined upper posture, body, body, body, back at an angle back at an angle of back at an angle of back at an angle of Angle of upper body...
  • Page 130: Seat Post

    Operation 6.4.3 Seat post 6.4.4 Saddle 6.4.3.1 Adjusting the seat post to body weight 6.4.4.1 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 131 Operation 6.4.4.2 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 108: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
  • Page 132 Operation 6.4.4.3 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 133 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 134 Operation 6.4.4.6 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 135 Operation 6.4.4.9 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 136 Operation 6.4.4.10 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 137: Handlebars

    Operation 6.4.5 Handlebars 6.4.5.1 Replacing the handlebars 6.4.5.3 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 138 Operation 6.4.5.4 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 139: Stem

    Operation 6.4.6 Stem 6.4.6.1 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 140 Operation 6.4.6.5 Setting the quill stem 6.4.6.6 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 141: Handles

    Operation 6.4.7 Handles 6.4.7.1 Replacing the handles 6.4.7.2 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 142: Tyres

    Operation 6.4.8 Tyres 6.4.8.1 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 143 Operation 2 Perform a visual check on tyres. Figure 129: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 130: Far too little tyre pressure MY24HM2 - 12_1.0_30.01.2024...
  • Page 144: Brake

    Operation 6.4.9 Brake 6.4.9.3 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 145 Operation 6.4.9.4 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 146 Operation 6.4.9.6 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 147 Operation 6.4.9.7 Adjusting the grip distance on a SHIMANO ST-EF41 handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the  Turn setting screw anti-clockwise towards rider’s requirements. Such adjustment does not minus (–). affect the pressure point or the position of the ...
  • Page 148 Operation 6.4.9.8 Adjusting the grip distance on SHIMANO handbrakes Only applies to pedelecs with this equipment Handbrake with Reach Adjust On brake levers with the Reach Adjust feature, the  Turn setting screw anti-clockwise towards grip distance of the handbrake can be adjusted minus (–).
  • Page 149 Operation Handbrake with Free Stroke On brake levers with the Free Stroke function,  Turn the setting screw (1) anti-clockwise there is a degree of free play before the brake towards minus (–). Make sure that the brake linings (3) touch the brake disc (4). As a result, linings do not touch the brake disc.
  • Page 150: Control Panel And Gear Shift

    Operation 6.4.10 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 151: Suspension And Damping

    Operation 6.4.11 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 152 Operation 6.4.12.1 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 153 Operation 6.4.12.2 Adjusting the sag for SR SUNTOUR air suspension fork Only applies to pedelecs with this equipment 1 Turn the air valve cap (see Section 3.4.19.1) 3 Pump air suspension to the required pressure anti-clockwise away from the air valve level.
  • Page 154 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 155 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 156 Operation Aion35 Zeron35 Axon32 Mobie34-air Mobie45-air Rubber volume 4.3cc 4.3cc space Deflection [mm] … … … … … … … … … … … … … … … … … … … … … … … … … … … …...
  • Page 157 Operation 6.4.12.3 Adjusting the RockShox steel suspension fork sag Only applies to pedelecs with this equipment 1 Turn the sag setting wheel anti-clockwise until it stops.  The softest spring pre-tensioning is set. Figure 143: Sag (1) Setting Prohibited >30% Figure 141: Turning the sag setting wheel in (1) and out (2) High sensitivity 20…...
  • Page 158 Betrieb 6.4.12.4 Adjusting the RockShox air suspension fork sag Only applies to pedelecs with this equipment The pressure should be measured at an ambient 4 Pump the suspension fork to the required  temperature of 21 °C to 24 °C. pressure.
  • Page 159 Betrieb 10 Get off the pedelec without allowing it to Body weight Tyre pressure deflect. Measure or read the distance between the dust wiper and the O-ring. This measurement is the sag. The recommended < 55 < 34 < 2.3 sag is between 10% and 20% (hard) or 20% 55…...
  • Page 160 Betrieb Adjusting preload internally  Only your specialist dealer may make an internal adjustment to the preload. The air spring characteristic curve at the end of the stroke (i.e. the puncture resistance) can be adjusted using bottomless tokens to reduce the air spring volume.
  • Page 161: Adjusting The Rear Frame Damper Sag

    Operation 6.4.13 Adjusting the rear frame damper sag Negative deflection (sag) CAUTION The sag is the percentage of total spring deflec- tion that is compressed by the rider’s body weight, Crash caused by broken rear frame damper including equipment (such as a backpack), their If the rear frame damper's maximum air pressure seating position and frame geometry.
  • Page 162 Operation 6.4.13.1 Adjusting the SR Suntour rear frame damper sag Only applies to pedelecs with this equipment Every rear frame damper has a specific delivery After setting up the rear frame damper, check the air pressure ex works. These levels are starting sag to ensure that the recommended settings are points.
  • Page 163 Operation Shock absorber Distance deflection [mm] [mm] 18.75… 26.25 17.50… 24.50 25… 35 16.25… 22.75 15.00… 21.00 25… 30 13.75… 16.50 10.00… 12.50 9.00… 11.25 20… 25 8.00… 10.00 7.00… 8.75 6.00… 7.50 Table 262: Recommended sag for the rear frame damper 14 The air pressure must be adjusted if the required sag level is not reached.
  • Page 164 Operation Adjusting preload internally 1 Release all the air from the main reservoir. 2 Remove the O-ring from beneath the air chamber. 3 Rotate the high-pressure cuff (high volume) and press downwards. 4 Add or remove the required quantity of volume spacers.
  • Page 165 Operation 6.4.13.2 Adjusting the RockShox rear frame damper sag Only applies to pedelecs with this equipment Adjusting the suspension fork sag (see  Weight Air pressure Section 6.4.12). Pound per When adjusting the sag, ensure that all dampers  Kilogram Pound (lbs) square inch are in the open position, i.e.
  • Page 166 Operation 11 Read the sag value on the scale. The optimum sag percentage is 25%. The sag level may be adjusted by ± 5%, depending on the rider's preferences (20% to 30%). 12 The air pressure must be adjusted if the sag level is not reached.
  • Page 167: Adjusting The Suspension Fork Rebound Damper

    Operation 6.4.14 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 168 Operation 6.4.14.1 Adjusting the SR Suntour rebound damper suspension fork Only applies to pedelecs with this equipment Figure 152: Example of SR SUNTOUR rebound adjuster (suspension fork) (1) Adjusting the suspension fork sag (see  Section 6.4.12). 1 Turn the rebound adjuster (suspension fork) clockwise to the closed position until it stops.
  • Page 169 Operation 6.4.14.2 Adjusting the ROCKSHOX suspension fork rebound damper Only applies to pedelecs with this equipment Figure 153: Adjusting the ROCKSHOX rebound damping Adjusting the suspension fork sag (see  Section 6.4.12).  Turn the rebound adjuster (suspension fork) clockwise towards the tortoise symbol. ...
  • Page 170: Adjusting The Rear Frame Damper Rebound Damper

    Operation 6.4.15 Adjusting the rear frame damper rebound damper Only applies to pedelecs with this equipment Adjust the rebound damper so that the rear frame damper rebounds quickly but without bottoming out upwards. Bottoming out refers to occasions when the rear frame damper rebounds too quickly and stops moving abruptly once it has reached the full rebound distance.
  • Page 171 Operation 6.4.15.1 Adjusting the SR Suntour rear frame damper rebound damper Only applies to pedelecs with this equipment Figure 154: Position of SR Suntour rebound adjuster (rear frame damper) on rear frame damper Triair2 (a), Triair (b), EDGE- comp (c), EDGE (d) and RAIDON (e) ...
  • Page 172 Operation 6.4.15.2 Adjusting the ROCKSHOX rear frame damper rebound damper Only applies to pedelecs with this equipment Figure 155: The position and shape of the rebound adjuster (rear frame damper) depends on the model. Rebound adjusters are always red Adjusting the rear frame damper sag (see ...
  • Page 173: Riding Light

    Operation 6.4.16 Riding light 6.4.16.1 Replacing the headlight 6.4.16.2 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 174 Operation 6.4.16.4 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 175: Adjusting Shimano 5003 On-Board Computer

    Operation 6.4.17 Adjusting SHIMANO 5003 on-board computer 2 Place on-board computer into the position Adjust the position of the on-board computer to the rider's needs. where the rider can use the on-board computer with their thumb and/or index finger. 1 Undo attachment screw. 3 Tighten attachment screw.
  • Page 176: Adjusting The On-Board Computer

    Operation 6.4.18 Adjusting the on-board computer 3-switch control panel CAUTION Crash caused by distraction A lack of concentration while riding increases the risk of an accident. This may cause a crash with serious injuries.  Never allow yourself to be distracted by the on-board computer.
  • Page 177 Operation MTB control panel 6.4.18.1 Opening the settings menu You can only change the settings when you stop.   Press the button (on-board computer) or switch A (left). Press switch Y (left) or switch X (left) briefly repeatedly to move the cursor on the menu.
  • Page 178 Operation 6.4.18.3 Sets the language 6.4.18.4 Setting units The settings menu is now open. The settings menu is now open.    Press switch Y (left) or switch X (left) briefly  Press switch Y (left) or switch X (left) briefly repeatedly until LANGUAGE is displayed on repeatedly until UNIT is displayed on the the menu.
  • Page 179 Operation 6.4.18.5 Adjusting the clock 6.4.18.6 Setting the start ratio Set the hours and then the minutes. The values When the start-up [Start mode] is enabled, the can be changed quickly by holding down the Y selected start-up transmission is used when the switch (left) or X switch (left).
  • Page 180 Operation 6.4.18.8 Adjusting gear shift info 6.4.18.9 Adjusting the backlight You can choose whether gear shift info is The settings menu is now open.  displayed or not.  Press switch Y (left) or switch X (left) briefly repeatedly until BACKLIGHT is displayed on The settings menu is now open.
  • Page 181 Operation 6.4.18.11Adjusting the font colour 6.4.18.12Adjusts the beep sound The settings menu is now open. The settings menu is now open.    Press switch Y (left) or switch X (left) briefly  Press switch Y (left) or switch X (left) briefly repeatedly until FONT COLOUR is displayed repeatedly until SIGNAL is displayed on the on the menu.
  • Page 182: Adjusting Shimano 800 On-Board Computer

    Operation 6.4.19 Adjusting SHIMANO 800 on-board computer 3-switch control panel CAUTION Crash caused by distraction A lack of concentration while riding increases the risk of an accident. This may cause a crash with serious injuries.  Never allow yourself to be distracted by the on-board computer.
  • Page 183 Operation MTB control panel Control panel on the right side of the handlebars Switch Function WHEN R ID IN G Changing up Change down Switch between automatic and manual gear shift Control panel on the left side of the handlebars Figure 167: MTB control panel Switch Function...
  • Page 184: Opening The Settings Menu

    Operation 6.4.20 Opening the settings menu 6.4.21 Closing the settings menu 1 Press switch X or switch Y until EXIT is  You can only change the settings when you stop. selected. The main display screen appears.  2 Press the button (display) or switch A. 1 Press the button (display) or switch A.
  • Page 185 Operation 6.4.21.2 Setting units 6.4.21.3 Changing the displayed speed The settings menu is now open. If there is a difference between the speed  displayed on this product and the speed displayed 1 Press switch X or switch Y until on another device, the displayed value can be B RIGHT NE S S is highlighted.
  • Page 186 Operation 6.4.21.4 Adjusting the clock 6.4.21.5 Changing the brightness The settings menu is now open.  The settings menu is now open.  1 Press switch X or switch Y until C LO C K is 1 Press switch X or switch Y until highlighted.
  • Page 187 Operation 6.4.21.6 Changing the beep sound 6.4.21.7 Automatic light setting The settings menu is now open. The settings menu is now open.   1 Press switch X or switch Y until B E E P is 1 Press switch X or switch Y until S TA R T highlighted.
  • Page 188 Operation 6.4.21.8 Adjusting the start gear 6.4.21.9 Changing level of assistance Only applies to pedelecs with this equipment The ride comfort of the pedelec depends on the maximum torque of the drive unit and how much It is only possible to adjust the gear shift if using ...
  • Page 189 Operation 6.4.21.10Adjusts the gear shift 6.4.21.11RD protection reset Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment It is only possible to adjust the gear shift if using It is only possible to perform the RD protection ...
  • Page 190: Connecting An External Device

    Operation 6.4.22 Connecting an external device 6.4.21.12Deleting all saved values The saved TRIP value (distance travelled) can be 6.4.22.1 Connecting device via the ANT cleared together with TIME (trip time), AVG 1 Switch on the drive system. (average speed) and MAX (maximum speed). There are two ways to do this.
  • Page 191: Accessories

    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 192: Trailer

    Operation 6.5.3 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 6.5.2 Trailer suitable pannier rack. The specialist dealer must install the pannier rack the first time to ensure that it is safely fitted.
  • Page 193: Personal Protective Equipment And Accessories For Road Safety

    Operation Personal protective equipment and accessories for road safety 6.6.1 Riding in bike parks and off-road 1 The helmet must have a reflective strip or a light in a clearly visible colour. Special protective equipment is mandatory when 2 Cycle clothing is essential at all times of year. you ride in bike parks.
  • Page 194: Before Each Ride

    Operation Before each ride  Check pedelec before each ride; see Section Checklist before each ride Check everything is sufficiently See Section  clean. Check guards. See Section 7.1.1  Check battery to ensure it is firmly See Section 6.17.2 ...
  • Page 195: Using The Battery

    Operation Using the battery 6.8.2 Inserting the battery Switch off the battery and the electric drive  system before removing or inserting the battery. Always hold battery with both hands to ensure  safe handling. 6.8.1 Removing the battery Figure 179: Inserting the battery 1 Place the battery into the battery lower mount with the contacts facing the front (1).
  • Page 196: Charging The Battery

    Operation 6.8.3 Charging the battery  The ambient temperature during the charging process must be within the range from 0 °C to 40 °C. The battery can remain on the pedelec or can be  removed for charging. Interrupting the charging process does not ...
  • Page 197: Straightening The Quickly Adjustable Stem

    Operation Straightening the quickly 6.10 Using the pannier rack adjustable stem CAUTION Only applies to pedelecs with this equipment 1 Open stem clamping lever. Crash caused by loaded pannier rack The pedelec is handled differently with a loaded pannier rack, in particular when the rider needs to steer and brake.
  • Page 198: Raising The Kickstand

    Operation 6.12.1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the leather to dry out and fade.  Park pedelec in the shade.  Always use a saddle cover. Moisture may cause the leather to detach from material beneath and mould may form.
  • Page 199: Setting The Saddle Height With The Remote Control

    Operation 6.14 Setting the saddle height with the 6.16 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. 6.14.1 Lowering the saddle ...
  • Page 200: Using Bar Ends

    Operation 6.16.2 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 201: Adjusting The Rear Frame Damper

    Operation 6.16.4 Adjusting the rear frame damper  Before each ride, adjust the suspension and/or damping to the terrain if you have a rear frame damper. Terrain Position Suspension Setting off Open Uphill or tarmacked roads Lock out Energy saved while riding on roads and/or for Threshold maximum pedalling efficiency on flat or smooth terrain...
  • Page 202 Operation 6.16.4.2 Locking out the ROCKSHOX rear frame 6.16.4.4 Adjusting the ROCKSHOX rear frame damper damper threshold Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment Adjusting the rear frame damper rebound damper The pedelec's sag is configured. ...
  • Page 203 Operation 6.16.4.5 Locking the SR SUNTOUR rear frame 6.16.4.6 Opening the SR SUNTOUR rear frame damper damper Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment The pedelec's sag is configured.  CAUTION The pedelec's rebound damping has been set. ...
  • Page 204: Adjusting The Rear Frame Damper Compression Damper

    Operation 6.16.5 Adjusting the rear frame damper compression damper When optimally adjusted, the rear frame damper The saddle rises slightly when absorbing a bump deflects quickly and unhindered when the bike hits (green line). bumps and absorbs a bump. Traction is retained The compression damper has two settings: (blue line).
  • Page 205 Operation 6.16.5.1 Adjusting the SR SUNTOUR rear frame damper 3C compression damper Only applies to pedelecs with this equipment The OPEN setting is suitable for light riders or for dry, dusty terrain where maximum traction is CAUTION required. Crash caused by damaged rear frame damper Medium setting The rear frame damper can be damaged if it is compressed under high stress load.
  • Page 206 Operation 6.16.5.2 Adjusting the SR SUNTOUR rear frame damper 2C compression damper Only applies to pedelecs with this equipment damper circuit. As a result, the rear frame damper responds with maximum sensitivity to the ground. CAUTION The OPEN setting is suitable for light riders or for Crash caused by damaged rear frame damper dry, dusty terrain where maximum traction is The rear frame damper can be damaged if it is...
  • Page 207 Operation 6.16.5.3 Adjusting the SR SUNTOUR rear frame damper low-speed compression damper Only applies to pedelecs with this equipment SR SUNTUR EDGE LOR8 rear frame dampers Hard setting [FIRM] feature a low-speed damper with two settings: The rear frame damper moves more slowly during OPEN and FIRM.
  • Page 208: Using The Shimano Electric Drive System

    Operation 6.17 Using the SHIMANO electric 6.17.1.2 Switching on using the battery drive system 6.17.1 Switching on the drive system CAUTION Crash caused by lack of readiness for braking When it is switched on, the drive system can be activated by the application of force on the pedals.
  • Page 209: Using The On-Board Computer

     1 Hold down button down until the push assist symbol is shown.  The push assist symbol is shown. The push assist is activated. Figure 195: SHIMANO SC-E5003 on-board computer Up button Select button Down button Light button Figure 196: Activated push assist symbol (1) 2 Push pedelec while pressing the down button at the same time.
  • Page 210: Selecting The Level Of Assistance

    Operation 6.18.5 Resetting the trip distance (DST)  The push assist system helps with pushing the pedelec. The speed can be a maximum of 1 Press the select button repeatedly. 6 km/h in this case.  The trip distance (DST) is displayed. 3 Release down button.
  • Page 211: Using The On-Board Computer

    Operation 6.19 Using the on-board computer 5-switch switch control panel CAUTION Crash caused by distraction A lack of concentration while riding increases the risk of an accident. This may cause a crash with serious injuries.  Never allow yourself to be distracted by the on-board computer.
  • Page 212: Using The Riding Light

    Operation 2-switch switch control panel Switch control panel functions on left Switch Function When riding: increase level of assistance When adjusting: move cursor or change the settings When riding: reduce level of assistance When adjusting: move cursor or change the settings When riding: change start screen display When adjusting: change display screen/confirm...
  • Page 213: Switching The Journey Information

    Operation 6.19.3 Switching the journey information 6.19.2.1 Select WALK level of assistance  Press switch Y (left) for about 2 seconds. The displayed journey information can be switched.  The level of assistance WAL K is displayed.  Press the button (display) or switch A (left) ...
  • Page 214 Operation  Press switch Y (left) or switch X (left) briefly 6.19.3.3 Clearing the journey information repeatedly to move the cursor on the menu. The TRIP distance completed can be deleted. TIME, AVG and MAX are also deleted if the trip Display Function distance is deleted.
  • Page 215: Using The On-Board Computer

    Operation 6.20 Using the on-board computer 3-switch control panel CAUTION Crash caused by distraction A lack of concentration while riding increases the risk of an accident. This may cause a crash with serious injuries.  Never allow yourself to be distracted by the on-board computer.
  • Page 216: Using The Riding Light

    Operation MTB control panel The on-board computer has one button (1) and a display screen (2). Figure 206: MTB control panel Figure 207: SC-EM800 on-board computer details Switch Y Switch X Switch Function Control panel on the right side of the WHEN R ID IN G handlebars BUT T ON...
  • Page 217: Using The Push Assist System

    Operation 6.20.4 Switching the journey information 6.20.3 Using the push assist system The displayed journey information can be switched. CAUTION Injury caused by pedals The pedals turn when using the push assist due to the system design.  You must steer the pedelec securely with both Figure 208: Changing from main display screen to DST hands when using push assist.
  • Page 218: Using The Brake

    Operation 6.21 Using the brake 6.21.1 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 219: Gear Shift

    Operation 6.22 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 220: Use Suspension And Damping

    Operation 6.23 Use suspension and damping 6.23.1 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 221: Adjusting The Suspension Fork Compression Damper

    Operation 6.23.2 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 222 Operation 6.23.2.1 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 223 Operation 6.23.2.2 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 224 Operation 6.23.2.3 Locking the ROCKSHOX suspension fork out Only applies to pedelecs with this equipment Race Day Damper RLC R RL/TK RL/TK (Paragon) Table 297: Lockout on the fork crown on ROCKSHOX suspension forks Opening the suspension Locking the suspension ...
  • Page 225 Operation 6.23.2.4 Adjusting the ROCKSHOX suspension fork threshold Only applies to pedelecs with this equipment RCT3 RTCT R Table 298: ROCKSHOX threshold (2) setting on the fork crown Adjusting the threshold  Lockout at Position 2 on the fork crown. ...
  • Page 226 Operation 6.23.2.5 Using ROCKSHOX high-speed compression damping Only applies to pedelecs with this equipment The high-speed damper is effective for: • stronger impacts • small, rapid impacts (e.g. stairs) • landings after quick, successive jumps. RCT3/RLC RC2 (Charger 2.1) RC2 (Charger 3) Table 299: High-speed lever (1) on the ROCKSHOX suspension fork crown Setting the high-speed damper to hard ...
  • Page 227: Parking

    Operation 6.24 Parking 6 Remove battery to protect against theft (see Notice Section 6.7.1.1). 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 228: Screwing In The Quickly Adjustable Stem

    Operation 6.24.1 Screwing in the quickly adjustable 6.24.2 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 229: Cleaning, Maintenance And Inspection

    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 230 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 231 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 7.5.11.2 shift...
  • Page 232 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 233: Before Each Ride

    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 234: Checking The Suspension Seat Post

    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 235: After Each Ride

    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 236: Basic Cleaning

    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 237: Cleaning The Frame, Fork, Pannier Rack, Guards And Kickstand

    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 238: Cleaning The Saddle

    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 239 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 240 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 241 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 242 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 243 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 244 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 245 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 246 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 247 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 248 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 249 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 250 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 251 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 252 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 253 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 254 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 232: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 227: Example of a KMC gauge Figure 233: Lower gauge to the left Figure 228: Example of a SHIMANO gauge...
  • Page 255 Cleaning, maintenance and inspection 7.5.4 Checking the belt  The tooth profile is pointed and teeth have worn thinner. Contact specialist dealer. The belt sprocket does need to be replaced. 7.5.4.1 Checking the belt for wear  Check belt for indications of wear: Figure 236: Indications of wear on a belt Figure 238: Worn tooth profile 1 Carbon tensile fibres are exposed...
  • Page 256 Cleaning, maintenance and inspection There are three common methods of measuring 1 Open app. belt tension: 2 Click on the voltage symbol. • Gates Carbon Drive mobile app for iPhone® and 3 Click on MEASURE. Android®, • Gates Krikit tension meter and 4 Point phone microphone towards the belt.
  • Page 257 Cleaning, maintenance and inspection 3 Press the check gauge down with just one ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 242: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.
  • Page 258 Cleaning, maintenance and inspection 7.5.5 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 259 Cleaning, maintenance and inspection 7.5.6 Checking the stem 7.5.9 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 260 Cleaning, maintenance and inspection 7.5.11 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 261 Cleaning, maintenance and inspection 7.5.11.5 Adjusting the ROHLOFF hub 7.5.11.6 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 262 Cleaning, maintenance and inspection 7.5.11.8 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. MY24HM2 - 12_1.0_30.01.2024...
  • Page 263 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. The tasks require technical Vibrations produced while riding can cause expertise, special tools and special lubricants. screws and springs that were tightened during The pedelec may become damaged if the pedelec manufacture to settle or come loose.
  • Page 264 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 265 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 266 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 267 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 268 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 7.5.6 …...
  • Page 269 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 270 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 271 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 272 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 273 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 274 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 275 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 276 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 277 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 278 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 279 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 280 Description 8.5.10 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 281 Description 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 2 … 4 Nm...
  • Page 282 Description SHIMANO for 5-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] SHIMANO for 6-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] TEKTRO for hydraulic disc brake system Attachment screws 4 … 6 Nm Torx®...
  • Page 283 Description SR SUNTOUR Damping side, top, aluminium 20 Nm SR SUNTOUR Damping side, bottom, without adjuster 10 Nm SR SUNTOUR Damping side, bottom, with adjuster 7 Nm SR SUNTOUR Fork head clamps 7 Nm SRAM RockShox, 35 Cover cap 28 Nm socket nut, 24 mm SRAM RockShox, Lyrik, Compression damper cover...
  • Page 284 Description SRAM RockShox Locking screw – remote control stop ring Hand-tight or 0.1 … 0.3 Nm 2 mm hex bit SRAM RockShox, Lyrik, Clamping screw – rebound adjuster ring 0.84 Nm 2.5 mm hex bit SRAM RockShox, Lyrik, Air suspension guide rod insert (Select+, Select, Base –...
  • Page 285 Description SHIMANO, FC-M8000, single version Attachment screw for crank/ chainring 12 … 14 Nm Star bit [no. 30] SHIMANO, FC-M8000, dual version Largest chainring 12 … 14 Nm Star bit [no. 30] Smallest chainring 16 … 17 Nm Star bit [no. 30] SHIMANO, FC-M8000, triple version Largest chainring...
  • Page 286 Description BOSCH motor BDU37xx 20 ± 2 Nm Torx Plus® P40, M8 × 16 6 x attachment screws for motor BOSCH Intuvia 100 bracket Torx ® Torx Plus ® Motor cover BOSCH motor cover BDU37xx Attachment screws for lower Initial fitting: 3 ± 0.5 Nm Torx®...
  • Page 287 Description ROHLOFF, 14/500 Chain tensioner attachment screw 8 Nm 5 mm hex bit ROHLOFF, 14/500 Chain guide attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Rear spacer sleeve attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Attachment screw for shift handle on handlebars 1 Nm 2.5 mm hex bit...
  • Page 288 Description SHIMANO, HB-M7000, HB-M6000 HB-M4050 Lock nut 10 … 15 Nm Hub spanner, 13 mm and 17 mm SHIMANO, HB-M7010, HB-M7010-B HB-M6010, HB-M6010-B, HB-M618, HB-M618-B, HB-MT400, HB-MT400-B Lock nut 21 … 26 Nm Hub spanner, 22 mm SHIMANO hub dynamo E2 model 20 - 25 Nm Screw wrench...
  • Page 289 Description SHIMANO DEORE XT SL-M8100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE XT SL-M8130 Attachment screw 3 Nm 4 mm hex bit SHIMANO, SLX SL-M7100 Attachment screw 3 Nm 4 mm hex bit SHIMANO XTR SL-M9100 Attachment screw 3 Nm 4 mm hex bit SRAM AXS Controller...
  • Page 290 Description SHIMANO for MTB/trekking Inner bearing adapter 35 … 50 Nm … SHIMANO for MTB/trekking Top swing screw, clip type 5 … 7 Nm Hex key, 5 mm/ and e-type Screw wrench, 9 mm SHIMANO for MTB/trekking Down swing screw, clip type, 5 …...
  • Page 291 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 292 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 293 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 294 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 295 Troubleshooting, fault clearance and repair SHIMANO 5003 drive system troubleshooting The components of the drive system are checked 6 Clean all the contacts with a soft cloth. constantly and automatically. If an error is 7 Insert the battery. detected, an error message appears on the 8 Start the drive system.
  • Page 296 Troubleshooting, fault clearance and repair Symptom Cause Remedy The journey distance can be shorter Check battery charge level. depending on the road conditions, the Recharge the battery if it is almost flat. gear level and the entire light usage time. The battery does not perform as well in This is not a malfunction.
  • Page 297 Troubleshooting, fault clearance and repair Symptom Cause Remedy The battery does not start  Replace battery with new one. The battery may be at the end of its charging when the charger service life. is connected. Interrupt charging process. Wait a moment. The temperature of the battery or the The battery and charger charger may have exceeded the operating...
  • Page 298 Troubleshooting, fault clearance and repair 9.5.1 On-board computer error Symptom Cause Remedy The battery charge level may be insuffi-  Charge the battery. cient.  Press the On-Off button (battery) to switch the power Is the power switched on?  If the battery is fitted to the pedelec and is being charged, No data is shown on the Is the battery charged? it cannot be switched on.
  • Page 299 Operation System messages 9.7.1 On-board computer warnings Figure 257: Example: Warning W000 Code Cause Limitation Remedy W101 No vehicle speed signal was The maximum speed at which  Contact your specialist dealer. (W011) detected by the speed assistance is provided is lower sensor.
  • Page 300 Operation 9.7.2 Error message screen If an error message is shown over the entire display, follow the procedure indicated below to reset the screen. 1 Press the On-Off button (battery). 2 Remove the battery from the mount. 3 Replace the battery. 4 Start the system.
  • Page 301 Operation 9.7.3 Maintenance indicator The maintenance symbol is displayed when maintenance is required.  Contact your specialist dealer. Figure 259: Maintenance symbol indicator 9.7.4 Battery error message The battery indicates errors with different LED Symbols: statuses. LED on LED off LED flashing Type Status...
  • Page 302 Troubleshooting, fault clearance and repair SHIMANO 800 drive system troubleshooting The components of the drive system are checked 8 Start the drive system. constantly and automatically. If an error is 9 If the drive system does not start up, remove detected, an error message appears on the the battery.
  • Page 303 Troubleshooting, fault clearance and repair Symptom Cause Remedy Are the pedals being pushed? The pedelec is not a motorbike. Push the pedals. Is the system switched on? Press On-Off button (battery) to switch on the system. Assistance is not Set the assistance mode to a different level of assistance than available.
  • Page 304 Troubleshooting, fault clearance and repair 9.8.4 Battery error 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. 21 Disconnect the charger mains plug. Is the charger mains plug firmly 22 Insert the mains plug.
  • Page 305 Troubleshooting, fault clearance and repair Symptom Cause Remedy 45 Remove the battery from the pedelec immediately. There is an unusual smell. 46 Contact the fire service. 47 Observe all the warnings in Section 2 Safety. 48 Remove the battery from the pedelec immediately. Fumes are emitted from the battery.
  • Page 306 Troubleshooting, fault clearance and repair 9.8.7 Other errors Symptom Cause Remedy  Two beeps will sound if a This is not a malfunction. switch is pressed but the Pressed switch mode has been deacti- switch cannot be vated. operated.  A fault or warning has occurred.
  • Page 307 Operation Error messages 9.9.1 Battery error message The battery indicates errors with different LED statuses. The LED light patterns are lit ( non-lit ( ) and flashing ( Type Status Lighting pattern Remedy System error Communication error with Check that the charging cable is firmly and properly the pedelec system.
  • Page 308 Operation On-board computer warnings 9.9.2 Figure 260: Example: Warning W000 Code Cause Limitation Remedy W101 No vehicle speed signal was The maximum speed at which  Contact your specialist dealer. (W011) detected by the speed assistance is provided is lower sensor.
  • Page 309 Operation 9.10 Error message screen If an error message is shown over the entire display, follow the procedure indicated below to reset the screen. 1 Press the On-Off button (battery). 2 Remove the battery from the mount. 3 Replace the battery. 4 Start the system.
  • Page 310 Troubleshooting, fault clearance and repair 9.10.1 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 311 Troubleshooting, fault clearance and repair 9.10.2 Correcting faults in the SR SUNTOUR suspension fork 9.10.2.1 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 312 Troubleshooting, fault clearance and repair 9.10.2.2 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 313 Troubleshooting, fault clearance and repair 9.10.2.3 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 266: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
  • Page 314 Troubleshooting, fault clearance and repair 9.10.2.4 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 315 Troubleshooting, fault clearance and repair 9.10.3 Correcting faults in the ROCKSHOX suspension fork 9.10.3.1 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 316 Troubleshooting, fault clearance and repair 9.10.3.2 Rebounding too slowly The suspension fork does not rebound quickly The suspension fork remains in a deflected state, enough after absorbing a bump. The suspension causing the headset and handlebars to move to a fork also remains deflected over subsequent lower position.
  • Page 317 Troubleshooting, fault clearance and repair 9.10.3.3 Suspension too soft on inclines The suspension fork deflects at a low point in the weight shifts forward, and the pedelec loses some terrain. The deflection is quickly used up, body momentum. Figure 272: Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 273: Adjust the compression adjuster so that it is harder...
  • Page 318 Troubleshooting, fault clearance and repair 9.10.3.4 Excessively hard damping on bumps When the bike hits a bump, the suspension fork The headset and handlebars are deflected deflects too slowly and the wheel lifts up from the upwards significantly, which can impair control. bump.
  • Page 319 Troubleshooting, fault clearance and repair 9.10.4 Correcting faults in the SR SUNTOUR rear frame damper 9.10.4.1 Rebound too fast The rear frame damper rebounds too quickly, Saddle and handlebars are deflected upwards producing a "pogo stick" effect or causing the bike when the wheel bounces back from the ground.
  • Page 320 Troubleshooting, fault clearance and repair 9.10.4.2 Rebounding too slowly The rear frame damper does not rebound quickly The rear frame damper remains in a deflected enough after a bump has been compensated and state after contact with the first bump. When the is not in the required initial position when the rear wheel hits the second bump, the saddle wheel hits the next bump.
  • Page 321 Troubleshooting, fault clearance and repair 9.10.4.3 Suspension too soft on inclines The rear frame damper deflects deeply through used up, body weight shifts downwards and the the deflection range. The deflection is quickly pedelec loses some momentum. Figure 280: Excessively soft suspension in the rear frame damper on hilly terrain Solution ...
  • Page 322 Troubleshooting, fault clearance and repair 9.10.4.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.
  • Page 323 Troubleshooting, fault clearance and repair 9.10.5 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 324 Troubleshooting, fault clearance and repair 9.10.6 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 325 Troubleshooting, fault clearance and repair 9.10.9 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 326 Troubleshooting, fault clearance and repair 9.11 Repairs at the specialist dealer 9.11.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.11.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...
  • Page 327 Troubleshooting, fault clearance and repair 9.11.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 9.11.5 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 328 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 329 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 330 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 331 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 332 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 333 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 334 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 335 Documents Notes MY24HM2 - 12_1.0_30.01.2024...
  • Page 336 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 337 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 338 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 339 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 340 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: 23-Q-0039 NOS FS SUV 2.1...
  • Page 341 – Part 2: Lithium • EN 17404 Cycles – Electrically power assisted cycles – EPAC mountain bikes. Cologne, 21.09.2023 ……………………………………………………………………………………………… Georg Honkomp, Managing Director, HERCULES GmbH MY24HM2 - 12_1.0_30.01.2024...
  • Page 342 Appendix RED Declaration of Conformity MODEL: SC-EM800 RI-7H90D-000 Regional regulatory information Europe Česky [Czech] Tímto SHIMANO INC. prohlašuje, že typ rádiového zařízení SC-EM800 je v souladu se směrnicí 2014/53/EU. Úplné znění EU prohlášení o shodě je k dispozici na této internetové adrese: http://si.shimano.com Dansk [Danish] Hermed erklærer SHIMANO INC., at radioudstyrstypen SC-EM800 er i overensstemmelse med direktiv 2014/53/EU.
  • Page 343 Appendix Canada Korea This device complies with Industry Canada license-exempt RSS standards. Operation is MSIP-CRM-WY7-SWAN-2 R-R-WY7-3A subject to the following two conditions: 1. this device may not cause interference, and 2. this device must accept any interference, including interference that may cause undesired operation of the device.
  • Page 344 Appendix III. Declaration of Conformity for incomplete machine 2006/42/EC DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY (Original) SHIMANO INC. 1. Business name and full address of the manufacturer and, where appropriate, his authorized representative; SHIMANO INC. 3-77 Oimatsu-cho, Sakai-ku, Sakai City, Osaka, Japan 2.
  • Page 345 Appendix MY24HM2 - 12_1.0_30.01.2024...
  • Page 346 Keyword index Keyword index Brake calliper, 77 CE marking, 336 position, 77 Chain guard 18, 22, 33 Air valve, 62 torque, 281 Chain guard, position, 62 Brake disc, 77 - clean, 240 Articulated shaft, - check, 252 torques 285 - maintain 244 - clean 239 Chain stay, 52 Axle,...
  • Page 347 Keyword index Display 89, 91 Front wheel, see Wheel Hub gear, Display, 86 Function display, 89, 91 - check 260 - charge battery, 176, 182, Hub, 75 - adjust ROHLOFF 261 Gear hub, - charging the battery, 209, - clean, 238 - inspect, 275 - maintain 244 Gear recommendation, 89, 91,...
  • Page 348 Keyword index LIMOTEC seat post, Parts list, 340 - adjust SR Suntour rebound - fit 116 Patent seat post, 80 damper, 171 Pedal, - adjust SR Suntour sag, 162 - clean, 235 - adjust threshold, 204 Maintenance, 337 - fit 122 - check 233 Manufacturer, 337 - maintain, 244...
  • Page 349 Keyword index Safety guards, 18, 22 Suspension seat post 80 Winter break, see Break in Sag 54 Suspension seat post, operation Sag setting wheel, - clean, 235 Work environment, 339 position, 62 - maintain, 243 Sag, Switching element, Year of manufacture, 339 setting wheel 69 - clean, 238 setting wheel, 67, 68, 70...

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