Page 1 KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for i:SY pedelecs with BOSCH Kiox 300/500 on-board computer E5 ZR F CX | E5 ZR F CX Century | E5 ZR F CX my i:SY | N3.8 ZR CX Comfort RE 14 ZR F | S10 Adventure | XXL E5 ZR F CX | XXL RE 14 ZR F XXL N3.8 ZR CX Comfort...
Page 2: Table Of Contents
Data privacy information Description Proper use 3.1.1 Pedelec type 3.1.2 Improper use 3.1.3 Area of use as per EN 17406, from model year 2024 Technical data 3.2.1 Complete BOSCH vehicle 3.2.2 Dimensions Nameplate 3.3.1 Model year 24 Nameplate Components 3.5.1 Overview 3.5.2 Chassis 3.5.3...
Page 3 Contents 3.5.9 Electric drive system Description of controls and screens 3.6.1 Handlebars 3.6.2 BOSCH LED Remote on-board computer 3.6.3 Handbrake 3.6.4 Suspension and damping 3.6.5 Battery level indicator (battery) Transportation 3.7.1 Using the transport securing system 3.7.2 Transporting the pedelec 3.7.3...
Page 4 Contents 6.5.1 Child seat 6.5.2 Trailer 6.5.3 MonkeyLoad system 6.5.4 Front baskets 6.5.5 Panniers and cargo boxes 6.5.6 Mobile holder 6.5.7 Saddle 6.5.8 Seat post 6.5.9 Bar ends 6.5.10 Protective covers 6.5.11 ROHLOFF gear hub tool Personal protective equipment and accessories for road safety Before each ride Using the battery 6.8.1...
Page 5 Contents 7.1.4 Checking the rear frame damper 7.1.5 Checking the pannier rack 7.1.6 Checking the mudguards 7.1.7 Check wheel concentricity 7.1.8 Checking the quick releases 7.1.9 Checking the suspension seat post 7.1.10 Checking the bell 7.1.11 Checking the handles 7.1.12 Checking the USB cover 7.1.13 Checking the riding light...
Page 6 Contents Inspection 7.5.1 Checking the wheel 7.5.2 Checking the brake system 7.5.3 Checking the chain 7.5.4 Checking the belt 7.5.5 Checking the riding light 7.5.6 Checking the stem 7.5.7 Checking the handlebars 7.5.8 Checking the saddle 7.5.9 Checking the seat post 7.5.10 Checking the pedal 7.5.11...
Page 7 Contents 9.4.1 Original parts and lubricants 9.4.2 Repairing the frame 9.4.3 Repairing the suspension fork 9.4.4 Replacing the riding light 9.4.5 Adjusting the headlight 9.4.6 Checking suspension fork-tyre clearance 9.4.7 Replacing pedelec components if lock function is installed Recycling and disposal 10.1 Guidelines on removal of waste Documents...
Page 8 About these operating instructions Thank you for your trust! Copyright I:SY pedelecs are premium quality vehicles. You © i:SY GmbH Co. KG have made an excellent choice. Your specialist dealer will provide you with guidance and Distribution or reproduction of these operating instruction and will assemble your product.
Page 9: About These Operating Instructions
About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and i:SY GmbH Co. KG actions. You will find three categories of warnings Hauptstraße 34 in the operating instructions: 32609 Hüllhorst Germany WARNING Tel.: +49 5744 900 910 Email: info@iSY.de May lead to serious or even fatal injuries if...
Page 10: Aim Of The Operating Instructions
About these operating instructions Aim of the operating instructions These operating instructions are not a substitute for personal instruction by the specialist dealer supplying the bike. These operating instructions Section are an integral part of the pedelec. Therefore, if it is re-sold at a later time, they must be handed over to the subsequent owner.
Page 11: 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 associate the pedelec with the Type no.
Page 12: 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 13 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 14: 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 15: 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 16: Toxic Substances
Safety Toxic substances 2.2.2 Irritants and If substances are released or used which pose a corrosive risk to people and the environment, effective substances protective measures must be taken. Possible hazards, contamination and health Corrosive substances (also known as corrosives) hazards due to: destroy living tissue or attack surfaces.
Page 17: Personal Protective Equipment
Safety Personal protective equipment Safety markings and safety instructions  Wear a suitable helmet. The helmet must have a reflective strip or a light in a clearly visible Pedelec and battery nameplates contain the colour. following safety markings and safety instructions: ...
Page 18: What To Do In An Emergency
Safety What to do in an emergency After contact with eyes 1 Rinse eyes under flowing water for at least ten 2.8.1 Dangerous situation in road traffic minutes with the lids open; also rinse under lids.  If you encounter any hazards or dangers in road traffic, apply the brake on the pedelec 2 Immediately consult a doctor in case of any until it comes to a halt.
Page 19: Battery Vapour Emission
Safety 2.8.3 Battery vapour emission 2.8.4 Battery fire Vapours may be emitted if the battery is damaged The safety electronics may fail if the battery is or used improperly. The vapours may cause damaged or faulty. The residual voltage can respiratory tract irritation.
Page 20: Data Privacy Information
When the pedelec is connected to the diagnosis tool at the specialist dealer’s, data is transferred to BOSCH eBike Systems (Robert Bosch GmbH) on the use of the Bosch drive unit, including its energy consumption and temperature, to help improve the product.
Page 21: Description
Description Description Proper use All checklists and instructions for actions in these reflectors and other components when riding on operating instructions met. Approved accessories public roads. The general laws and the can be installed by specialist staff. regulations for the prevention of accidents and environmental protection in the respective country Use the pedelec when it is in perfect, proper of use must be adhered to.
Page 22: Area Of Use As Per En 17406, From Model Year 2024
Description 3.1.3 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 23 Description 3.1.3.1 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 24: Technical Data
Description Technical data 3.2.1 Complete BOSCH vehicle 3.2.1.2 Environmental requirements You can be ride the pedelec within a temperature range between -5 °C and +40 °C. The electric Power output/system 250 W (0.25 kW) drive system is limited in its performance outside...
Page 25: Dimensions
Description 3.2.2 Dimensions The pedelec may only be loaded to its maximum The maximum permitted total weight is permitted total weight (PTW). • the weight of the fully assembled pedelec • plus body weight • plus baggage Type no. Model PTW [kg] Ready-to-use weight [kg] Max.
Page 26: Nameplate
Description Nameplate 3.3.1 Model year 24 i:SY GmbH Co. KG Longericher Str. 2 The nameplate is situated on the frame. The 50739 Köln, Germany precise position of the nameplate is shown in TYP: A-06 Figure 3. EPAC nach EN 15194 The nameplate contains up to twelve pieces of information.
Page 27: Nameplate
Description Nameplate The nameplate is situated on the frame. The The nameplate contains up to twelve pieces of precise position of the nameplate is shown in information. Figure 3. i:SY GmbH Co. KG Hauptstr. 34 32609 Hüllhorst, Germany Typ: A-01 EPAC nach EN 15194...
Page 28: Components
Description Components 3.5.1 Overview 19 20 21 22 25 26 Figure 4: Pedelec viewed from the right Wheel Nameplate Disc brake Seat post Belt Fork Saddle Rechargeable battery Guard Pannier rack Chain guard Front light Rear light Motor Steering headset Reflector Folding pedal Handlebar extension...
Page 29 Pedal variant VP COMP, VP-F55 Folding pedal; see Section # Crank set #, Magan 4 (110058) Crank length: 160 mm; for BOSCH Gen4, ISIS SHIMANO, CN-HG54 Chain, # links; see Section # Chain/belt variant SHIMANO, CN-LG500 Chain, # links; see Section #...
Page 30 SHIMANO, TIAGRA SL-4700 Shifter with indicator, 10-speed BOSCH, Performance Line CX/Cargo Motor See Section 3.5.06.1 [BDU3740](EB11.100.001) On-board computer BOSCH, LED Remote [BRC3600] (BRC3600) See Section # Display BOSCH, Kiox 300 [BHU3600] (EB13.100.003) See Section # BOSCH, PowerPack 600 [BBP3560] (EB12.100.00M)
Page 31 # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, CDX-B-118 (11M-118T-12CT) teeth: 118; width: 12 mm; length: 1298 mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX Belt sprocket, 46T Chain guard HORN, Catena A08/38 Plastic, #129203 Sprocket/belt sprocket/ GATES®, SHIMANO Inter-5E SF 6L combined...
Page 32 Documents BOSCH, PowerPack 600 [BBP3560] (EB12.100.00M) Battery variant BOSCH, PowerPack Frame 545 [BBP3550] (EB12.100.02J) Charging current (max.): 4 A, 220-240 V; see Charger BOSCH, 4A charger [BPC3400] (EB12.110.001) charger instructions 3-finger brake lever | Length: 1100 mm | Hydraulic Brake, front, variant 1...
Page 33 Chain wheel/belt sprocket Chain guard HORN, Catena … Chain guide … … Motor BOSCH™, Performance Line CX (BDU3740) See Section 3.6.7 On-board computer BOSCH™, LED Remote (BRC3600) See Section 3.6.5 Display BOSCH™, Kiox 300 (BHU3600) See Section 3.6.6 Display mount (BDS3YYY) See Section 3.6.7...
Page 34 Documents Brake lever TEKTRO, HD-T532 3-finger lever Front | Rear Brake TEKTRO, HD-T532 Hydraulic disc brake Front | Rear 4 pistons| 2 pistons Brake disc TEKTRO, TR180 | TEKTRO, TR160 Steel, Ø 180 mm | Ø 160 mm Front | Rear …...
Page 35 # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, 118T CDX (11M-118T-12CT) teeth: 118; width: 12 mm; length: # mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX Belt sprocket, 46T Chain guard HORN, Catena A08/38 Plastic, #129203 Sprocket/belt sprocket/ GATES®, SHIMANO Inter-5E SF 6L combined...
Page 36 Documents # 3-finger brake lever | Length: 1800 mm | Rear brake TEKTRO, # HD-T532 Hydraulic disc brake, 2-piston Front brake disc TEKTRO, TR-45 Ø: 180 mm Rear brake disc TEKTRO, TR-45 Ø: 160 mm Light cable length: 1300 mm; remote control cable: Headlight FUXON, FF-100 EB-HB 1200 mm;...
Page 37 # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, 118T CDX (11M-118T-12CT) teeth: 118; width: 12 mm; length: # mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX Belt sprocket, 46T Chain guard HORN, Catena A08/38 Plastic, #129203 Sprocket/belt sprocket/ GATES®, SHIMANO Inter-5E SF 6L combined...
Page 38 Drawing: R30.358.00, with KlickFix Pannier rack, rear HAOJIE, HJ11CA12-21-03 (QC-A186AA) Drawing: HJ11CA12-21-03 (QC-A186AA) Design motor cover for Performance Line CX Left Motor cover guard BOSCH, EB11.200.00Y (BDU374Y); see Section # Guard, rear SKS, PET A65 R275 20" Drawing: 6744-790 Guard, front SKS, PET A65 R275 20"...
Page 39 # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, 120T CDX (11M-120T-12C) teeth: 120; width: 12 mm; length: 1320 mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX Belt sprocket, 55T Chain guard HORN, Catena A08/38 Plastic, #129203 GATES®, 22T ENVIOLO CDX (CT1122VMN)
Page 40 Documents # 3-finger brake lever | Length: 1200 mm | Front brake TEKTRO, # HD-T532 Hydraulic disc brake, 2-piston # 3-finger brake lever | Length: 1800 mm | Rear brake TEKTRO, # HD-T532 Hydraulic disc brake, 2-piston Rear brake disc TEKTRO, TR-17 Ø: 160 mm Front brake disc...
Page 41 VP COMP, VP-F55 Folding pedal; see Section # Crank set #, Magan 3 (110017) Crank length: 170 mm; for BOSCH Gen3, ISIS # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, 125T CDX (11M-125T-12CT) teeth: 125; width: 12 mm; length: # mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX...
Page 42 Documents BOSCH, PowerPack 600 [BBP3560] Rechargeable battery (EB12.100.00M) BOSCH, PowerPack Frame 545 [BBP3550] Rechargeable battery (EB12.100.02J) Charging current (max.): 4 A, 220-240 V; see Charger BOSCH, 4A charger [BPC3400] (EB12.110.001) charger instructions 3-finger brake lever | Length: 1800 mm | Hydraulic...
Page 43 Chain wheel/belt sprocket Chain guard HORN, Catena … Chain guide … … Motor BOSCH™, Performance Line CX (BDU3740) See Section 3.6.7 On-board computer BOSCH™, LED Remote (BRC3600) See Section 3.6.5 Display BOSCH™, Kiox 300 (BHU3600) See Section 3.6.6 Display mount (BDS3YYY) See Section 3.6.7...
Page 44 Documents Rechargeable battery BOSCH™, PowerPack 545 (#) See Section 3.6.8 Charger BOSCH™, 4A Charger (BPC3400) Charger, charging current (max.): 4 A Brake lever TEKTRO, HD-T532 3-finger lever Front | Rear Brake TEKTRO, HD-T532 Hydraulic disc brake Front | Rear 4 pistons| 2 pistons...
Page 45 Folding pedal; see Section # Crank set #, Magan 3 (110017) Crank length: 170 mm; for BOSCH Gen3, ISIS # Belt, polyurethane/carbon; pitch: 11, number of Chain/belt GATES®, 125T CDX (11M-125T-12CT) teeth: 125; width: 12 mm; length: # mm Chain wheel/belt sprocket GATES®, BOSCH GEN4 Spider unit CDX...
Page 46 Documents Charging current (max.): 4 A, 220-240 V; see Charger BOSCH, 4A charger [BPC3400] (EB12.110.001) charger instructions # 3-finger brake lever | Length: 1200 mm | Front brake TEKTRO, # HD-T532 Hydraulic disc brake, 2-piston # 3-finger brake lever | Length: 1800 mm |...
Page 47: Chassis
Description 3.5.2 Chassis 3.5.2.2 Steering system The steering system components are: The chassis comprises two components: • Steering headset, • frame and • Stem, • steering system. • Handlebars • Fork. 3.5.2.1 Frame 3.5.2.3 Steering headset The frame absorbs all forces which act on pedelec from body weight, pedalling and the ground.
Page 48 Description 3.5.2.5 Handlebars The pedelec is steered using the handlebars. The handlebars are used to support the upper body and is the mount for operating and display components (see Section 3.5.1). Figure 8: Handlebar dimensions The main dimensions of handlebars are: Rise (height) Width Backsweep...
Page 49: Suspension
Description 3.5.3 Suspension 3.5.2.6 Fork The stem and handlebars are attached to the top The suspension system in the pedelec comprises end of the fork steerer. The axle is fastened to the 2 components: fork ends. The wheel is fastened to the axle. •...
Page 50 Description 3.5.3.2 Tyre suspension The tyre pressure has a great effect on ride comfort. Tyres with a high tyre pressure transmit more impacts from uneven roads to the frame and handlebars than tyres with low air pressure. Soft tyres do not deflect; they absorb smaller bumps in the road thanks to the tyre's sag and ability to deform.
Page 51 Description 3.5.3.3 Suspension fork Damping The stem and handlebars are attached to the top After compressing, the suspension fork returns to end of the fork steerer. The axle is fastened to the its original position. If there is a damper, it will fork ends.
Page 52 Description Parts of a suspension fork Figure 12: Parts of a suspension fork Fork steerer Tyre clearance Sag adjuster (without damper) or Lockout or Tyre height Push button Tyre passage width Fork crown Deflection (suspension fork) Side view Damper side (optional) Installation height Quick release Offset...
Page 53 Description Suspension fork assembly groups A suspension fork can feature up to three different assembly groups: • Compression damper (blue) • Rebound damper (red) • Air suspension or steel spring (orange) Figure 14: Internal structure of a steel suspension fork Einstellrad SAG Damping adjuster Compression dampers...
Page 54 Description Lock The compression can be disabled in any or on optimally tarmacked roads. This increases suspension fork. A suspension fork will then energy consumption and reduces propulsion. It behave like a rigid fork. thus makes sense to lock the suspension on tarmacked roads and when riding uphill.
Page 55 Description Figure 17: Optimum suspension fork ride performance over bumps Rebound dampers Rebound dampers damp rebound movements, i.e. The damper rebounds at a controlled speed if the rebound stress loads. suspension fork is optimally adjusted. The wheel stays in contact with the ground when passing Rebound damping determines the speed at which over bumps (blue line).
Page 56 Description Compression dampers 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 57 Description Low-speed compression dampers The low-speed compression damper (also A slow deflection speed is generated in the abbreviated to LSC from low-speed compression) suspension fork when riding over bumps. The low- is a specialised compression damper. speed damper controls the suspension fork's behaviour positively in such riding situations.
Page 58 Description 3.5.3.4 SR SUNTOUR, MOBIE34-CGO BOOST DS LO 15AH2-110 20" Maximum rider weight for SR SUNTOUR steel suspension fork SR SUNTOUR steel suspension forks are available in three different hardness types for different body weights: Medium Coil spring model Soft Hard/rigid Fitted as standard Max.
Page 59 Description 3.5.3.5 SR SUNTOUR cartridge LO The SR Suntour LO cartridge features • a compression damper 2. 2. • a rebound damper Before riding, use the rebound adjuster (fork) (1) to adjust the system to the surface you will ride on. You can use the compression adjuster (2) remote control to open and close the damping.
Page 60: Wheel
Description 3.5.4 Wheel Tyre pressure The permitted pressure range is indicated on the side of the tyre. It is indicated in psi or bars. The tyre is only able to support the pedelec if there is adequate tyre pressure. The tyre pressure must be adjusted to the body weight and then checked on a regular basis.
Page 61 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 62 Description Bead core 3.5.4.3 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 63 Description Presta valve 3.5.4.6 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 64 Description 3.5.4.7 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 65: Brake
Description 3.5.5 Brake 3.5.5.2 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 66 Description 3.5.5.3 Disc brake Figure 35: 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 67 Description 3.5.5.4 Back-pedal brake Figure 36: Brake system with a back-pedal brake – example Rear wheel rim brake Handlebars with brake lever Front wheel rim brake Pedal Backpedal brake The back-pedal brake is an extra brake. The back- pedal brake stops the rear wheel from moving by pushing the pedals in the opposite direction to the direction of travel.
Page 68: Saddle
Description 3.5.6 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 69 Description 3.5.6.1 Ladies’ saddle 3.5.6.2 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 70: Seat Post
Description 3.5.7 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 71: Mechanical Drive System
Description 3.5.8 Mechanical drive system 3.5.8.1 Chain drive layout The pedelec is driven by muscle power, just like a bicycle. The force which is applied by pedalling in the direction of travel drives the front chain wheel. The chain or belt transmits the force onto the rear chain wheel and then onto the rear wheel.
Page 72 Description 3.5.8.3 Folding pedal The rider applies physical to the mechanical drive system with their feet, driving it forward. The left pedal has a left-handed thread and the right crank has a right-handed threaded to prevent them from coming loose. The pedal has a standard thread of 9/16"...
Page 73: Electric Drive System
Motor assistance is lower when 3.5.9.4 Rechargeable battery little muscle power is used than when muscle BOSCH batteries are lithium ion batteries which power is used. This happens regardless of the are developed and manufactured to the latest level of assistance.
Page 74 Description In the event of a hazard, a protective circuit switches the battery off automatically. In the event of a hazard, a protective circuit switches the battery off automatically. The battery has a high energy content when charged. The code of practice for their safe handling is found in Section 2 Safety and Section 6.9 Rechargeable battery in the operating instructions.
Page 75 It controls the system and all indicators on the display screen using six buttons. Figure 52: BOSCH Kiox 300 and Kiox 500 displays The display switches off automatically if it is Figure 51: BOSCH LED Remote on-board computer removed from its mount.
Page 76 Description 3.5.9.7 Lighting Lighting includes: • The front light (also known as the headlight or front lamp) • The rear light (also known as the rear lamp) The headlight and the rear light are also on whenever the riding light is activated. 3.5.9.8 FUXON front light, FS-100 EB main beam with main beam switch The FUXON front light, FS-100 EB main beam features a reflector and a main beam switch.
Page 77: Description Of Controls And Screens
Description Description of controls and screens 3.6.1 Handlebars Figure 54: Detailed view of handlebars with BOSCH Kiox 300, example 1, 7 Handle Front wheel handbrake (behind handlebars) Rear wheel handbrake (behind handlebars) Bell Main beam switch Twist shifter Display Kiox300 LED Remote control panel MY23I0a - 42_1.0_22.01.2024...
Page 78: Bosch Led Remote On-Board Computer
BOSCH LED Remote on-board computer The on-board computer on the handlebars is used as a control panel. It controls the system and all indicators on the display screen using six buttons. Figure 55: Overview of BOSCH LED Remote on-board computer Decrease brightness button/ <...
Page 79 Description 3.6.2.1 Selected level of assistance indicator 3.6.2.3 Battery level indicator (on-board com- puter) The higher the selected level of assistance, the The battery level indicator (on-board computer) more the drive system assists with pedalling. shows the battery charge level. You can also see eMTB mode is available for Performance Line CX the battery charge level on the LEDs on the drives.
Page 80 Description Flash sequence Capacity Flash sequence Capacity 60 … 69% 10 … 19% 50 … 59% 0 … 9% Red LED is 40 … 49% flashing: The uppermost bar will flash if the battery is charging. 3.6.2.4 System message 30 … 39% The on-board computer indicates whether a critical or less critical error has arisen in the drive system.
Page 81 Software updates are automatically transferred to smartphone to record activities. the on-board computer in the background of the BOSCH eBike Flow smartphone app as soon as The rider needs to agree to location data being the app is connected to the on-board computer.
Page 82 Description 3.6.2.7 Lock function When the lock function is used, the on-board computer acts in a similar way to a key for the drive system. Once the lock function is switched on, the e-bike drive unit assistance is deactivated by removing the on-board computer. The rider can continue to use the mechanical drive system.
Page 83 Ø GESCHW. km/h 20.5 MAX. GESCHW. km/h 29.2 Figure 56: BOSCH Kiox 300 and Kiox 500 displays The following screens are shown on the display screen: • S TA R T SCRE E N, see Section 3.4.8.1 Figure 58: Overview of start screen, screen 2 •...
Page 84 Description 3.6.2 .10 S TA TUS S CR EE N Level of assistance You open the STATUS SCREEN by pressing the When the drive system is switched on, the motor assistance is switched off. <- button on the START SCREEN. You can open The pedelec can be used like a normal the settings on this screen.
Page 85 Description 3. 6. 2 .11 TRIP S CREE N 3.6.2 .12 R A N GE SC RE E N You open the TRIP SCREEN by pressing the You open the RANGE SCREEN by pressing the >- button on the START SCREEN. >- button on the START SCREEN.
Page 86 Description 3. 6. 2 .13 FIT NE SS S CR EE N 3.6.2 .14 A BS S CRE EN You open the FITNESS SCREEN by pressing the Only applies to pedelecs with this equipment >- button on the start screen. You open the ABS screen by pressing the >- button on the START SCREEN.
Page 87 Description 3. 6. 2 .15 S E TTING S All system and service-relevant values can be read and changed in the settings. The settings menu structure is customised and may change when components or services are added. Menu Submenu My eBike →...
Page 88: Handbrake
Description 3.6.3 Handbrake There is a handbrake on the left and right of the handlebars. Figure 67: 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 89 Description 3.6.3.1 SHIMANO SL-T6000 derailleur gears Only applies to vehicles with this equipment The gear shift unit is on the left of the handlebars. The gear shift unit features two switches and an indicator. Figure 68: SHIMANO SL-T6000 gear shift 1 Gear indicator 2 Lever A (gear shift) 3 Lever B (gear shift)
Page 90 Description 3.6.3.2 SHIMANO NEXUS SL-C7000-5 twist grip shifter Only applies to vehicles with this equipment SHIMANO hub gears feature a NEXUS SL-C7000-5 twist grip shifter with an indicator on the right of the handlebars. Figure 69: SHIMANO NEXUS SL-C7000-5 twist grip shifter Twist grip shifter Gear indicator You change gears by turning the twist grip shifter.
Page 91 Description 3.6.3.3 ROHLOFF 500/14 hub gear Only applies to vehicles with this equipment You can switch gears individually after one another or skipping over several speeds on the ROHLOFF Speedhub 500/14 gear hub using a twist shifter. Figure 70: ROHLOFF gear shift Twist shifter When you change gears, coupling elements Gear indicator...
Page 92: Suspension And Damping
Description 3.6.4 Suspension and damping 3.6.4.1 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 93: Battery Level Indicator (Battery)
Description 3.6.5 Battery level indicator (battery) Each battery has its own level indicator. All five LEDs will light up when the battery is fully charged. The charge level for the activated battery is also shown on the on-board computer. If the battery level falls below 5%, all the LEDs on the operating status and battery level indicator will go out.
Page 94: Transportation
Transporting and storing Transportation 3.7.2 Transporting the pedelec 3.7.2.1 By car CAUTION Bicycle rack systems which use the handlebars or frame to hold the pedelec in an upside-down Crash caused by unintentional activation position exert inadmissible forces on its There is a risk of injury if the drive system is components during transportation.
Page 95: Shipping A Pedelec
Transporting and storing 3.7.4 Transporting the battery 3.7.2.3 By local transport Batteries are subject to hazardous goods You can normally take pedelecs on local public regulations. Undamaged batteries may be transport, e.g. by bus or suburban rail, if you transported by private persons in road traffic. purchase a bike ticket.
Page 96: Storing
Transporting and storing Storing  Always store pedelec, battery, on-board New battery computer, display and charger separately. Inspect battery for damage after delivery.  Storage temperature +10 °C … +40 °C  If batteries are faulty, observe instructions in Humidity 30%…85% Handling a damaged or faulty battery during storage and disposal (see Section 2.1.1).
Page 97: Break In Operation
Transporting and storing 3.8.4 Break in operation 3.8.4.1 Preparing for a break in operation 1 The pedelec needs to be cleaned with a damp Notice cloth and preserved with wax spray. Never wax the friction surfaces of the brake. Batteries discharge if they are not used. If the 2 Have the specialist dealer carry out battery is stored for a longer period of time when maintenance and basic cleaning and apply...
Page 98: Assembly
Assembly Assembly Scope of delivery WARNING 1 × pre-assembled pedelec  Risk of eye injury 1 × front wheel  Problems may arise if components are set 2 × pedals  incorrectly. They may cause serious injuries to 2 × quick releases (optional) ...
Page 99: Commissioning
Assembly Commissioning Only trained specialist staff may perform initial commissioning since initial commissioning of the pedelec requires special tools and specialist knowledge. Experience has shown that a pedelec which has not yet been sold is automatically handed to customers as soon as it appears ready to ride. It makes sense to prepare each pedelec so that it is fully ready for use immediately after being assembled.
Page 100: Adjusting The Suspension System To Body Weight
Assembly 5.3.2 Adjusting the suspension system to body weight Not included in price 5.3.2.1 Adjusting SR Suntour suspension elements Seat post and forks are components that may be § Not included in price replaced after approval by the vehicle or parts manufacturer.
Page 101: Preparing The Wheel
Assembly 5.3.3 Preparing the wheel There is an arrow on the sides of the tyres with the • The FRONT rotation direction arrow indicates the recommended direction of rotation for the front inscription ROTATION to show the direction of wheel. rotation.
Page 102: Installing The Wheel In The Suntour Fork
Assembly 5.3.4 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.4.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this equipment Before installing the wheel, ensure that the O-ring 4 Insert the securing screw on the non-drive ...
Page 103 Assembly 5.3.4.2 20 mm cross axle Only applies to Suntour forks with this 2 Tighten the cross axle with the red handle. equipment CAUTION Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
Page 104 Assembly 5 Check the position and clamping force of the quick release lever. The quick release lever must be flush with the shock absorber. Figure 85: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 105 Assembly 5.3.4.3 Q-LOC quick release Only applies to Suntour forks with this equipment 1 Push in the quick release until you can hear a click. Make sure that the flange is extended. CAUTION Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel.
Page 106: Checking The Stem And Handlebars
Assembly 5.3.5 Checking the stem and handlebars 5.3.5.1 Checking the connections 5.3.5.3 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 107: Assembly Instructions For Online Sales
Assembly Assembly instructions for online Scope of delivery sales 1 pedelec with battery  Your specialist dealer will complete assembly and 2 pedals (already greased)  commissioning for this pedelec. The pedals were 1 charger  unscrewed and the handlebars repositioned before transportation.
Page 108: Straightening The Handlebars
Assembly 5.5.4 Straightening the handlebars 5.5.4.2 Stem with clamping lever version II Only applies to pedelecs with this equipment The handlebars must be turned so that they are parallel to the frame and tyres for transportation. 1 Open the clamping lever on the stem quick 1 Turn handlebars clockwise until they are release.
Page 109: Checking The Stem And Handlebars Are In Correct Position
Assembly 5.6.1 Checking the stem and handlebars are in correct position 5.6.1.1 Checking the connections 5.6.1.3 Checking the bearing clearance 1 Place the fingers of one hand on the upper 1 Stand in front of the pedelec. Clamp the front headset cup.
Page 110: Fitting The Pedals
Assembly 5.6.2 Fitting the pedals 3 Turn the pedal marked R anti-clockwise by The pedals have two different threads to ensure 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 111: 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 112 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 113: 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 114: 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 115: Determining The Sitting Position
Operation 6.4.2 Determining the sitting position The starting point for a comfortable posture is the Position on roadster Position on city bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.
Page 116: 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 117 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 98: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
Page 118 Operation 6.4.4.3 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 119 Operation Using calculation Depending on the position, the following value is added to the minimum saddle width. Position on roadster + 4 cm Position on city bike + 3 cm Position on trekking bike + 2 cm Position on sports bike + 1 cm Triathlon/time trials + 0 cm...
Page 120 Operation 6.4.4.6 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 121 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 122 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 123: 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 124 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 125: 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 126 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 127: 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 128: Tyres
Operation 6.4.8 Tyres 6.4.8.1 Adjusting tyre pressure Tyre pressure in bar for body weight It is not possible to offer a general recommended Tyre width about about about tyre pressure for a particular pedelec or tyre. The 60 kg 80 kg 110 kg correct tyre pressure largely depends on the weight load on the tyres, mainly determined by...
Page 129: 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 130 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 131 Operation 6.4.9.6 Setting the grip distance for a MAGURA handbrake disc brake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the rider’s requirements. Such adjustment does not WARNING affect the pressure point or the position of the Crash caused by incorrectly set grip distance brake linings.
Page 132 Operation 6.4.9.7 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 133 Operation 6.4.9.8 Setting the grip distance on a TEKTRO handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the Notice rider’s requirements.  Undo 2 mm setting screw anti-clockwise. If the setting screw is fully removed, components inside the handbrake will also be permanently ...
Page 134: 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 135 Operation 6.4.10.2 Registering the Rohloff gear hub Only applies to pedelecs with this equipment Each Rohloff hub has a unique consecutive serial number on its housing. Figure 129: ROHLOFF Speedhub 500/14 serial number You must register the gear hub so that Rohloff can provide servicing (maintenance, repair) and the warranty.
Page 136: 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 137 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 138: 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 139 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 140 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 32: Recommended sag for the rear frame damper 14 The air pressure must be adjusted if the required sag level is not reached.
Page 141 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 142: Riding Light
Operation 6.4.14 Riding light 6.4.14.1 Replacing the headlight 6.4.14.2 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 143 Operation 6.4.14.4 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 144: Adjusting Kiox 300 And Kiox 500 On-Board Computer
6.4.15.3 Update software user account first. Software updates are managed by the Bosch Registering on a PC eBike Flow smartphone app. 1 Create the user account on the BOSCH The on-board computer is now connected to the  website. smartphone.
Page 145 Operation Once the lock function is switched on, the pedelec 6.4.15.7 Securing the on-board computer (optional) can only be put into use if: It is possible to secure the on-board computer so • the configured smartphone is switched on, that it cannot be removed. The locking plate does •...
Page 146 Plus button/ light button Minus button/ – push assist button Table 33: Description of BOSCH LCD Remote operating elements You can use the select button (4) to perform the following functions: • Open the QUIC K ME NU while riding •...
Page 147 Operation 6.4.15.10Adjusting the on-board computer The pedelec is stationary. You cannot open and 6.4.15.11Selecting the language  adjust the settings while riding. 1 Open <System> menu item. Inserting the display.  2 Open < Language> sub-menu item. Switching on the electric drive system.
Page 148 Operation 6.4.15.16Reset settings 1 Open <System> menu item. 2 Open <Settings reset> sub-menu item. 3 Follow the instructions on the on-board computer.  All settings are reset to the factory settings. All user data has been cleared. MY23I0a - 42_1.0_22.01.2024...
Page 149: Accessories
Operation Accessories The following accessories are approved for i:SY pedelecs. 6.5.1 Child seat Notice Child seats may only be used with the vehicle §  Observe the legal regulations on the use of manufacturer's approval and only if they are child seats.
Page 150: Trailer
Operation 6.5.2 Trailer 6.5.1.1 THULE, Yepp Nexxt Maxi Trailers may only be used with the vehicle § manufacturer's approval and only if they are approved for use on e-bikes. CAUTION Crash caused by brake failure The braking distance may be longer if the trailer is carrying excessive load.
Page 151 Operation 6.5.2.1 Approval for trailer with SHIMANO hub 6.5.2.3 Approval for trailer with ROHLOFF hub Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment As a basic rule, it is permitted to use a trailer in ROHLOFF Speedhub 500/14 combination with any SHIMANO hub.
Page 152: Monkeyload System
Operation 6.5.3.2 Detaching MonkeyLoad system 6.5.3 MonkeyLoad system components The pannier rack is MonkeyLoad-ready, i.e. all 1 Open locked MonkeyLoad system with the key. MonkeyLoad system components can be used on 2 Pull on the pull knob gently. the pannier rack. Other systems such as I-Rack, racktime or MIK are not compatible.
Page 153: Front Baskets
Operation 6.5.4.2 i:SY, MIK Front Carrier 6.5.4 Front baskets Front baskets may only be used with the vehicle § manufacturer's approval and only if they are approved for use on e-bikes. 6.5.4.1 i:SY, KLICKfix Front Carrier Figure 144: i:SY, MIK Front Carrier •...
Page 154 Operation 6.5.4.3 i:SY, MAXI Front Carrier 6.5.4.4 i:SY, Lowrider Figure 145: i:SY, MAXI Front Carrier Figure 146: i:SY, Lowrider • Material: steel Attached to the fork; suitable for the watertight • Colour: black i:SY pannier rack bags • Dimensions: 45 x 16 x 29 cm (W x H x D) •...
Page 155: Panniers And Cargo Boxes
Operation 6.5.5.3 i:SY, Front Shopping Basket 6.5.5 Panniers and cargo boxes Panniers and cargo boxes are permitted if they § are approved for use on e-bikes. 6.5.5.1 BASIL, Buddy Dog Basket by i:SY Figure 149: i:SY, Front Shopping Basket Shopping basked for KLICKfix Front Carrier •...
Page 156: Mobile Holder
Operation 6.5.6 Mobile holder 6.5.6.2 Releasing the mobile This phone case, used as the base for the SP 1 Turn the mobile 90° to the left. Connect system, is mounted on the stem.  The fastener is released. Depending on the holder model, a mobile can either be fitted directly on the handlebars or on the 2 Remove mobile.
Page 157: Seat Post
Operation 6.5.8 Seat post 6.5.10 Protective covers Seat post are components that may be replaced § § Description Article number after approval by the vehicle or parts manufacturer. Only seat posts that are approved BY.SCHULZ, protective cover for Parallelogram suspension for use on e-bikes may be used to replace seat post existing ones.
Page 158: Personal Protective Equipment And Accessories For Road Safety
Operation Personal protective equipment and accessories for road safety Seeing and being seen is crucial in road traffic. 7 The two separate brakes on the pedelec must The following requirements must be met for riding work at all times. a pedelec safely on public roads. 8 The clear sounding bell must be fitted and must work.
Page 159: Using The Battery
Operation Using the battery Switch off the battery and the drive system before 3 Keep the lock open with the key.  removing or inserting the battery. 4 Push the battery upwards (3). 6.8.1 Inserting the battery  The battery can be heard locking into place. 5 Check battery to ensure it is firmly in place on The key is inserted in the lock.
Page 160: Charging The Battery
Operation 6.8.3 Charging the battery The battery can remain on the pedelec or can be removed for charging. Interrupting the charging process does not damage the battery. The battery is fitted with a temperature monitoring system which only allows charging within a temperature range between 0 °C and 40 °C.
Page 161: Straightening The Quickly Adjustable Stem
Operation Straightening the quickly 6.10 Lowering the pedals adjustable stem CAUTION Only applies to pedelecs with this equipment 1 Open stem clamping lever. Crushing fingers in the pedal folding latch The pedal folding latch uses a high clamping force. There is a risk of crushing fingers in the latch.
Page 162: Using The Pannier Rack
Operation 6.11 Using the pannier rack CAUTION 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. This can lead to a loss of control. This may cause a crash with injuries.
Page 163: Using The Leather Saddle
Operation 6.13.1 Using the leather saddle 6.16 Using the handlebars Sunlight and UV light tarnish the colour and cause  Wear heavily padded cycling gloves. the leather to dry out and fade.  This helps protect sensitive areas of your ...
Page 164: 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 165: Using The Electric Drive System
 Press the On-Off button (battery).  The battery level indicator (on-board computer) and the indicator for the selected level of assistance go out. Figure 164: Position of the On-Off button on the BOSCH LED Remote  The pedelec is switched off. MY23I0a - 42_1.0_22.01.2024...
Page 166: Using The On-Board Computer
 Keep the diagnosis port flap closed at all times to ensure no dust or moisture can penetrate through the port. Figure 165: Overview of BOSCH LED Remote on-board computer 6.18.2 Charging the control panel battery Symbol...
Page 167: Using The Riding Light
Operation 6.18.3 Using the riding light 6.18.5 Using the push assist system  The drive system needs to be already switched on to turn on the riding light. CAUTION Injury from pedals or wheels The pedals and the drive wheel turn when the push assist system is used.
Page 168: Selecting The Level Of Assistance
Operation 6.18.6 Selecting the level of assistance 1 Press Push assist button for longer than 1 seconds. Hold down the button. The control panel is used to set how much the  The battery level indicator goes out and a white electric drive should assist the rider when running light in the direction of travel indicates pedalling.
Page 169: Using The Brake
Operation 6.19 Using the brake 6.19.1 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 170: Gear Shift
Operation 6.20 Gear shift The selection of the appropriate gear is a prerequisite for a physically comfortable ride and making sure that the electric drive system functions properly. The ideal pedalling frequency is between 70 and 80 revolutions per minute. ...
Page 171: Using A Shimano Hub Gear
Operation 6.20.2 Using a SHIMANO hub gear Only applies to pedelecs with this equipment CAUTION Crash caused by incorrect use If the rider applies too much pressure on the pedals during a gear change and activates the shifter or changes several gears at a time, their feet may slip from the pedals.
Page 172: Using Eshift
Operation 6.20.3 Using eShift 6.20.3.2 Using eShift with manual SHIMANO DI2 hub gears eShift refers to the integration of electronic gear Only applies to pedelecs with this equipment shift systems into the electric drive system. The new gear is shown briefly on the on-board 6.20.3.1 Using eShift with SHIMANO DI2 computer each time it is changed.
Page 173: Using A Rohloff Gear Shift
Operation 6.20.4 Using a ROHLOFF gear shift Only applies to pedelecs with this equipment You turn the twist grip to shift gears with the ROHLOFF gear hub. WARNING Risk of falling if gear shift subject to high pedal load Shifting gears when applying great force to the pedals produces a strong, shock-like impact load on the coupling elements in the gear mechanism.
Page 174: Adjusting The Suspension Fork
Operation 6.21 Adjusting the suspension fork  Adjusting the suspension and damping on the suspension fork or on the remote control (suspension fork) while riding: Position Suspension Downhill rides and uneven terrain Open or OPEN Flat, hilly, even or slightly bumpy terrain or Threshold or uneven roads medium...
Page 175 Operation 6.21.1.1 Locking the SR SUNTOUR suspension fork Only applies to pedelecs with this equipment LORC-PCS LORC Table 36: Lockout on the fork crown on SR Suntour suspension forks  Turn lockout (1) on the fork crown clockwise to  Turn lockout (1) on the fork crown LOCK.
Page 176: Parking
Operation 6.22 Parking Checklist after each ride Notice Cleaning Heat or direct sunlight can cause the tyre pressure Lights and reflectors See Section 7.2.5  to increase above the permitted maximum Brake See Section 7.2.5  pressure. This can destroy the tyres. ...
Page 177: Screwing In The Quickly Adjustable Stem
Operation 6.22.1 Screwing in the quickly adjustable 4 Turn handlebars by 90° so that they are stem straight. 5 Close stem clamping lever. Only applies to pedelecs with this equipment Screw in the quickly adjustable stem to save 6.23 Folding up the pedal space when parking.
Page 178: Activating The Lock Function
Operation 6.23.1 Activating the lock function Only applies to pedelecs with this equipment  Remove the on-board computer used during set-up.  The lock function is activated. The drive system now provides no assistance However, the rider can continue to use the pedelec without assistance.
Page 179: 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 180 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 181 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 182 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 183: 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 184: 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 185: 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 186: 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 187: 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 188: 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 189: Cleaning The Cassette, Chain Wheels And Front Derailleur
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 190: Cleaning The Chain
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 191: Maintenance
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 192: Maintain Pannier Rack
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 193: Maintaining The Handles
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 194: Maintaining The Hub
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 195: Maintaining The Chain
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 196: Maintaining The Brake
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 197: Inspection
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 198 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 199 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 200 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 201: Checking The Brake System
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 202 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 203: Checking The Chain
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 204 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 192: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 187: Example of a KMC gauge Figure 193: Lower gauge to the left Figure 188: Example of a SHIMANO gauge...
Page 205: Checking The Belt
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 196: Indications of wear on a belt Figure 198: Worn tooth profile 1 Carbon tensile fibres are exposed...
Page 206 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 207 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 202: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.
Page 208: Checking The Riding Light
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 209: Checking The Stem
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 210: Checking The Gear Shift
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 211 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 212 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. MY23I0a - 42_1.0_22.01.2024...
Page 213: Inspection And Maintenance
Inspection and maintenance Inspection and maintenance Initial inspection Component-specific maintenance After 200 km or 4 weeks after purchase High-quality components require extra maintenance. Tasks require technical expertise, Vibrations produced while riding can cause special tools and special lubricants. The pedelec screws and springs that were tightened during may become damaged if the stipulated pedelec manufacture to settle or come loose.
Page 214 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 215 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 216: Carry Out Initial Inspection
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 217: Perform Major Inspection
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 218 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 219 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 220 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 221 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 222 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 223 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 224: Inspect Frame
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 225: Inspecting The Gear Hub
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 226: Inspecting The Axle With Quick Release
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 227: Inspecting The Fork
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 228: Inspecting The Seat Post
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 229 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 230: Torque
Mounting bracket 0.8 Nm Torx® T20 FIT Remote Display Mounting bracket 0.8 Nm Torx® T20 BOSCH Intuvia 100 bracket Attachment screw 1, M3 × 22 1 Nm 3 mm hex bit Attachment screw 2, M3× 14 1 Nm 3 mm hex bit...
Page 231 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 232 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 233 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 234 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 235 Chain guard Brose chain guard bash guard Attachment screws 6 Nm Hex key, 3 mm Chain guard for BOSCH Motor BDU37xx Attachment screws max. 10 Nm M6 × 10; head: max. 5 mm; length: max. 8.5-mm Crank bearing/crank set Conventional cartridge crank bearing 35 …...
Page 236 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 237 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 238 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 239 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 240 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 241: Troubleshooting, Fault Clearance And Repair
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 242: Sitting Discomfort
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 243: Pain In Shoulders And Nape Of Neck
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 244: Knee Pain
Troubleshooting, fault clearance and repair 9.1.7 Knee pain Pedelec riding is a sport that is easy on the knee Solution joints and is recommended for beginners. Very • Contact specialist dealer. Have the powerful forces are transmitted from the thigh to pedelec adjusted (see Section 6.5).
Page 245: Kiox 300 And Kiox 500 Drive System
Troubleshooting, fault clearance and repair Kiox 300 and Kiox 500 drive system More info on Kiox 300 Description The control panel indicates whether a critical or Adjusting less critical error has arisen in the drive system. Cleaning The error messages generated by the drive Maintenance system can be read in the eBike Flow app and by Error solution...
Page 246: Errors In Assistance Function
Troubleshooting, fault clearance and repair 9.2.2 Errors in assistance function Symptom Cause Remedy Assistance is not Is the battery charged sufficiently? Check battery is charged. available. Recharge the battery if it is almost flat. Is the system switched on?  Press On-Off button (battery). ...
Page 247: Battery Errors
Troubleshooting, fault clearance and repair 9.2.3 Battery errors Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace old battery with new one. very quickly. useful life. The battery cannot be Is the charger mains plug firmly Disconnect the charger mains plug and plug it in again.
Page 248: Display Screen Errors
Troubleshooting, fault clearance and repair Symptom Cause Remedy There is an unusual Remove from the battery immediately. smell. Contact the fire service immediately. Observe all the warnings in Section 2 Safety. Fumes are emitted from Remove from the battery immediately. the battery.
Page 249: Error Message
Operation Error message 9.3.1 On-board computer The on-board computer indicates whether a  Press selection button. critical or less critical error has arisen in the drive  The error is acknowledged and the indicator for system. the selected level of assistance displays the colour for the configured level of assistance The error messages generated by the drive permanently.
Page 250 Operation Description Method of resolution If a battery fault is detected, two  Contact specialist LEDs will flash on the battery dealer. level indicator. Code: No LEDs will light up if there is Check all plug connections. no power. Check contacts on the battery for dirt.
Page 251: Correcting Disc Brake Faults
Troubleshooting, fault clearance and repair 9.3.3 Correcting disc brake faults Symptom Cause Remedy Ringing and unusual  Contact specialist dealer. Fit a city or trekking tyre. sounds from disc brakes. Riding on asphalt with off-road tyres. Dirty or greasy brake disc. ...
Page 252: Correcting Faults In The Sr Suntour Suspension Fork
Troubleshooting, fault clearance and repair 9.3.4 Correcting faults in the SR SUNTOUR suspension fork 9.3.4.1 Rebound too fast The suspension fork rebounds too quickly, Fork head and handlebars are deflected upwards producing a "pogo stick" effect, where the wheel if the wheel bounces back from the ground. Body lifts from the ground in an uncontrolled way.
Page 253 Troubleshooting, fault clearance and repair 9.3.4.2 Rebounding too slowly The fork does not rebound quickly enough after The fork remains in a deflected state, causing the absorbing a bump. The fork also remains headset and handlebars to move to a lower deflected over subsequent bumps, which reduces position.
Page 254 Troubleshooting, fault clearance and repair 9.3.4.3 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 221: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
Page 255 Troubleshooting, fault clearance and repair 9.3.4.4 Excessively hard damping on bumps When the bike hits a bump, the fork deflects too The headset and handlebars are deflected slowly and the wheel lifts up from the bump. upwards significantly, which can impair control. Traction decreases when the wheel no longer touches the ground.
Page 256: Problems With Hub Gear
Troubleshooting, fault clearance and repair 9.3.5 Problems with hub gear Symptom Cause Remedy A noise is heard when the All gear speeds except 1. pedals are turning. A noise is heard when the pedelec is pushed All gear speeds except 1. backwards.
Page 257 Troubleshooting, fault clearance and repair Symptom Cause Remedy Strange noises occur  when the brakes are Contact specialist dealer. applied. Rotation feels stiff during  Contact specialist dealer. free rotation. Chain jumps between the  gearwheels when gear is Gearwheels and/or chain worn. Contact specialist dealer.
Page 258: Problems With Rohloff Hub Gear
Troubleshooting, fault clearance and repair 9.3.6 Problems with Rohloff hub gear The ROHLOFF Service Team can be reached at Shipping parts is very expensive or impossible in service@rohloff.de. The service strives to help some countries. That is why sufficient spare parts cyclists around the world with technical problems for components subject to wear or at risk of falling and purchasing spare parts.
Page 259 Troubleshooting, fault clearance and repair Symptom Cause Remedy Reduce the shift cable tension. Shift cable tension too high If the problem is not solved, contact your specialist dealer. Shift cables worn, dirty or damaged. Wrong shift cables fitted  Contact specialist dealer (fit new shift cables). Cable routing has too many bends or kinks.
Page 260 Troubleshooting, fault clearance and repair Symptom Cause Remedy Oil can form around the shaft seals, the housing lid gasket and the oil drain screw due to variations in air temperature and pressure. This is not a defect. Traces of oil film (no droplets) ...
Page 261: Correcting Freewheel Faults
Troubleshooting, fault clearance and repair 9.3.7 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 262: Correcting Lighting Faults
Troubleshooting, fault clearance and repair 9.3.8 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 263: Correcting Other Faults And Errors
Troubleshooting, fault clearance and repair 9.3.11 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 264: Repairs At The Specialist Dealer
Troubleshooting, fault clearance and repair Repairs at the specialist dealer 9.4.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.4.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...
Page 265: Replacing The Riding Light
Troubleshooting, fault clearance and repair 9.4.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 9.4.5 Adjusting the headlight  The headlight must be positioned so that its light beam shines on the road 10 m in front of the pedelec (see Section 6.4).
Page 266: Replacing Pedelec Components If Lock Function Is Installed
9.4.7 Replacing pedelec components if lock function is installed 9.4.7.1 Replacing a smartphone 1 Install Bosch eBike connect app on the new smartphone. 2 Log on using the same account which was used to activate the lock function. 3 Connect on-board computer with the smartphone while the on-board computer is in use.
Page 267: Recycling And Disposal
Recycling and disposal Recycling and disposal This device is marked according to the recycling saves reserves of raw materials and European Directive 2012/19/EU on ensures that all the regulations for protection of waste electrical and electronic health and the environment are adhered to when equipment –...
Page 268 Recycling and disposal Waste type Disposal Dispose of Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Cleaning cloths covered in biodegradable oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer.
Page 269: Documents
Documents 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 270 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 271: Inspection And Maintenance Log
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 272 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 273 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 274 Documents Notes MY23I0a - 42_1.0_22.01.2024...
Page 275: Charger Operating Instructions
Documents 11.3 Charger operating instructions MY23I0a - 42_1.0_22.01.2024...
Page 276 Documents 4A Charger MY23I0a - 42_1.0_22.01.2024...
Page 277 Documents MY23I0a - 42_1.0_22.01.2024...
Page 278 Documents MY23I0a - 42_1.0_22.01.2024...
Page 279 Documents MY23I0a - 42_1.0_22.01.2024...
Page 280 Documents MY23I0a - 42_1.0_22.01.2024...
Page 281 Documents MY23I0a - 42_1.0_22.01.2024...
Page 282: Glossary
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 283 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 284 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 285: Abbreviations
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 286: Appendix
Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* i:SY GmbH Co. KG 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: H-01 S10 Adventure City and trekking bicycle...
Page 287: Directive Declaration Of Conformity With Red Directive
Appendix Directive declaration of conformity with RED Directive LED Remote KIOX 300 Robert Bosch GmbH, Bosch eBike Systems, Robert Bosch GmbH, Bosch eBike Systems, hereby declares that the LED Remote radio hereby declares that the Kiox 300 radio system system type complies with Directive 2014/53/EU.
Page 288: Keyword Index
Keyword index Keyword index Brake disc, 66 CE marking, 282 - check, 202 Chain guard 17, 28 Air valve, 53 - clean 189 Chain guard, position, 53 - replace, 264 - clean, 190 Articulated shaft, position, 66 torques 235 - maintain 194 Brake lever, 66 Chain wheel, 71 Axle,...
Page 289 Keyword index electric, 73 Gear shift, Hydraulic brake system, Dual pivot rim brake, - adjust dual-cable, Bowden- - check 201 torque, 232 cable-operated twist grip Dunlop valve, see conventional shifter 211 Initial commissioning, 99 valve - check 210 Dust seal 59 - check electric gear shift, Jockey wheel, - switch gears, 91, 176...
Page 290 Keyword index Mountain bike, 283 - major inspection 213 Retainer guard, 74 Mountain bike, see MTB - sell, 106 Riding light, MTB, see mountain bike - service 191 - adjust, 143 Mudguard 17 - ship, 95 - check, 184, 208 Mudguard, - unpacking 98 - switch off 167...
Page 291 Keyword index Shut-off speed, 284 Tyres,- Tube-type tyres 60 Slicks, 61 Slippage, 284 Underride guard, Spare part, 284 torque, 240 Spoke nipples, 63 USB cover, - maintain, 194 - check 184 position, 60 USB port, Spokes, 63 - use, 166 - check, 200 - replace 264 position, 60...

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