Page 1 READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for KETTLER pedelecs PINION Motor, FIT Remote Basic and FIT Display PINNIATO FS SPORT, PINNIATO HT SPORT, PINNIATO HT COMFORT KN170-xxPD, KN170-xxPW, KN171-xxPD, KN171-xxPW, KN174-xxPD, KN174-xxPW...
Page 2: Table Of Contents
Contents Contents About these operating instructions Manufacturer Laws, standards and directives 1.2.1 Warnings 1.2.2 Markups For your information Language Aim of the operating instructions Type number and model Frame number Identifying the operating instructions Safety Residual risk 2.1.1 Risk of fire and explosion 2.1.2 Electric shock 2.1.3...
Page 3 Contents 3.5.7 PINION electric drive system 3.5.8 Control panel 3.5.9 Handlebars with FIT Remote Basic with FIT Comfort or FIT Compact display Description of controls and screens 3.6.1 Display 3.6.2 Handbrake 3.6.3 Gear shift 3.6.4 Suspension and damping 3.6.5 Suspension and damping on rear frame damper Transporting and storing Transportation 4.1.1...
Page 4 Contents Accessories 6.5.1 Trailer 6.5.2 Child seat 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 Suspension fork coil spring 6.5.8 Bar ends 6.5.9 Fixed weather protection systems 6.5.10 Additional battery headlight 6.5.11 Kickstand Personal protective equipment and accessories for road safety Before each ride Straightening the quickly adjustable stem...
Page 5 Contents 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 7.1.14 Checking the brake After each ride 7.2.1 Cleaning the riding light and reflectors...
Page 6 Contents 7.5.2 Checking the brake system 7.5.3 Checking the belt 7.5.4 Checking the riding light 7.5.5 Checking the stem 7.5.6 Checking the handlebars 7.5.7 Checking the saddle 7.5.8 Checking the seat post 7.5.9 Checking the pedal 7.5.10 Checking the gear shift Inspection and maintenance Initial inspection Major inspection...
Page 7 Contents Recycling and disposal 10.1 Guidelines on removal of waste Documents 11.1 Assembly report 11.2 Inspection and maintenance log Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Keyword index MY24K12 - 13_1.0_01.02.2024...
Page 8 About these operating instructions Thank you for your trust! Copyright KETTLER pedelecs are premium quality vehicles. © KETTLER Alu-Rad GmbH You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product.
Page 9: About These Operating Instructions
About these operating instructions About these operating instructions Manufacturer CAUTION KETTLER Alu-Rad GmbH Longericher Strasse 2 May lead to minor or moderate injuries if ignored. 50739 Köln Low-risk hazard. Germany Notice Tel.: +49 6805 6008-0 Fax: +49 6805 6008-3098 May lead to material damage if ignored.
Page 10: Language
About these operating instructions Language The original operating instructions are written in Section German. A translation is invalid without the original operating instructions. Manufacturer   Aim of the operating instructions Safety   These operating instructions are an integral part Description ...
Page 11: Type Number And Model
About these operating instructions ype number and model Frame number These operating instructions are an integral part of pedelecs with the type numbers: Each frame has an individual frame number Type no. Model Pedelec type stamped on it (see Figure 2). The frame number KN170-xxPD PINNIATO FS SPORT City trekking bicycle...
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 3.5.
Page 15: Toxic Substances
Safety Toxic substances 2.2.2 Toxic substances If substances are released or used which pose a risk to people and the environment, effective protective measures must be taken. Toxic substances (also known as poison or toxins) refer to substances which can cause damage to Possible hazards, contamination and health living beings if they enter the organism above a hazards due to:...
Page 16: Requirements For The Pedelec Rider
Safety Personal protective equipment Defective battery Liquids and vapours may leak from damaged or  Wear a suitable helmet. The helmet must have faulty batteries. Excessively high temperatures a reflective strip or a light in a clearly visible may also cause liquids and vapours to leak from colour.
Page 17: Safety Markings And Safety Instructions
Safety Safety markings and safety What to do in an emergency instructions 2.8.1 Dangerous situation in road traffic Pedelec and battery nameplates contain the following safety markings and safety instructions:  If you encounter any hazards or dangers in road traffic, apply the brake until the pedelec comes to a halt.
Page 18: Battery Vapour Emission
Safety After contact with eyes After skin contact 1 Rinse eyes under flowing water for at least ten 1 Remove any solid particles immediately. minutes with the lids open; also rinse under 2 Remove contaminated clothing immediately. lids. 3 Rinse the affected area with plenty of water for 2 Immediately consult a doctor in case of any at least 15 minutes.
Page 19: 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 20: 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 21: Technical Data For Entire Vehicle
Description Technical data for entire vehicle 3.2.1 Pinion Power output/system 250 W (0.25 kW) Shut-off speed 25 km/h Charging temperature 0 °C … +45 °C Operating temperature -20 °C … +45 °C Storage temperature +10 °C … +50 °C Work environment temperature +15 °C …...
Page 22: Weight
Description 3.2.2 Weight 3.2.3 Maximum permitted total weight (PTW) The pedelec may only be loaded to its maximum Type no. Model Weight [kg] permitted total weight (PTW). KN170-xxPD PINNIATO FS SPORT The maximum permitted total weight is KN170-xxPW PINNIATO FS SPORT •...
Page 23: Environmental Requirements
Description 3.2.4 Environmental requirements 3.2.4.1 Pinion You can be ride the pedelec within a temperature Temperatures under -10 °C and over +60 °C must range between -5 °C and +40 °C. The electric be avoided as a general rule. Never put the drive system is limited in its performance outside battery in a car in summer or store it in direct this temperature range.
Page 24: Model Year 24 Nameplate
Description Model year 24 nameplate The nameplate is situated on the frame. The exact KETTLER position of the nameplate is shown in Figure 3. Alu-Rad GmbH The nameplate contains up to twelve pieces of Longericher Str. 2 50739 Köln, Germany information.
Page 25: Nameplate
EN 15194 0,25 kW / 25 km/h zGG 150 kg EPAC 25 kg BJ 2022 Figure 3: Example KETTLER nameplate No. Designation Description More information The CE marking is a declaration by the manufacturer that the pedelec CE marking Appendix complies with applicable requirements.
Page 26: Components
Description Components 3.5.1 Overview PINNIATO HT 21 22 23 Figure 4: Pedelec viewed from right: PINNIATO HT used as example Front wheel Seat post Rear wheel brake Front wheel hub Saddle Belt Fork Pannier rack Belt guard Front wheel mudguard Rear light Crank Front light...
Page 27 Description PINNIATO FS 19 20 21 22 23 Figure 5: Pedelec viewed from right: PINNIATO FS used as example Front wheel Seat post Rear wheel brake Front wheel hub Saddle Belt Fork Pannier rack Belt guard Front wheel mudguard Rear light Rear frame damper Front light Rear wheel mudguard...
Page 28 Documents 3.5.1.1 Components and repair parts for PINNIATO FS SPORT KN170-xxPD, KN170-xxPD Diamant, Wave Shape: Diamant; size: 48 cm Shape: Diamant; size: 53 cm Shape: Diamant; size: 58 cm Frame HSUSHENG, Pinniato FS Sport Shape: Wave; size: 43 cm Shape: Wave; size: 48 cm Shape: Wave;...
Page 29 Documents GATES®, CDECDR Snubber Chain guide/snubber GATES®, CDECDRL Snubber PINION, P8557 Belt tensioner Sprocket/belt sprocket/ GATES®, 34T 9-Spline CDX Belt sprocket, 34T freewheel (CT1134SMN) Shifter PINION, P5580 Electric shifter Motor FIT, Pinion E1.12 (501070) See Section 3.5.06.1 On-board computer FIT, Remote Basic (500092) Without spacer;...
Page 30 Shape: Diamant; size: 55 cm Shape: Diamant; size: 50 cm Frame Shape: Diamant; size: 60 cm KETTLER, Pinniato HT Shape: Wave; size: 45 cm Shape: Wave; size: 50 cm Shape: Wave; size: 55 cm Size: ETRTO 60-622 (29 × 2.35 inches), version: DD,...
Page 31 Documents On-board computer FIT, Remote Basic (500092) Without spacer; see Section # Display FIT, Compact (500085) See Section # FIT, Ultracore 1100 Wh (501216.) # See Section # FIT, Ultracore 720 48 V 15 AH (500081) See Section # Rechargeable battery FIT, Ultracore 820 Wh (501215) # See Section # FIT, Ultracore 960 FIT 48 V 20 AH...
Page 32 Diamant, Wave Shape: Diamant; size: 50 cm Shape: Diamant; size: 55 cm Shape: Diamant; size: 60 cm Frame KETTLER, PINNIATO HT Shape: Wave; size: 45 cm Shape: Wave; size: 50 cm Shape: Wave; size: 55 cm Tyres CST, SUPERO ALL GROUND # Size: ETRTO 55-622 (28 ×...
Page 33 Documents Sprocket/belt sprocket/ GATES®, 32T 9-Spline CDX Belt sprocket, 32T freewheel (CT1132SMN) Shifter PINION, P5580 Electric shifter Motor FIT, Pinion E1.9 (501069) See Section 3.5.06.1 On-board computer FIT, Remote Basic (500092) Without spacer; see Section # Display FIT, Compact (500085) See Section # FIT, Ultracore 1100 Wh (501216.) # See Section #...
Page 34: Chassis
Description 3.5.2 Chassis Carbon frame The chassis comprises two components: Carbon (CFRP) is a carbon-fibre-reinforced polymer made of high-strength, rigid fibres. • Frame and Carbon frames comprise several layers of carbon • steering system with an epoxy resin matrix. The uppermost layer is known as the visible layer.
Page 35 Description Rider’s height [cm] Frame size [cm] Rider’s height [cm] Frame size [cm] 155… 165 160… 175 43… 48 46… 48 165… 175 48… 53 165… 180 49… 51 175… 185 53… 58 170… 185 52… 54 185… 195 58… 62 175…...
Page 36 Description 3.5.2.2 Rear frame damper A rear frame damper is primarily fitted to mountain bikes and helps to protect the pedelec and rider against impacts and vibrations caused by uneven ground. Rear frame damper suspension A rear frame damper deflects when a steel spring, it stays in contact with the ground instead air suspension, or both suspension types act on it.
Page 37 Description Rear frame damper damping After compressing, the suspension fork returns to A distinction is made between two types of its original position. If there is a damper, it will dampers: decelerate movement, preventing the suspension • Rebound dampers, system from springing back in an uncontrolled •...
Page 38 Description Compression damper The compression damper controls the When optimally adjusted, the rear frame damper compression lifting speed or amount by which the counteracts deflection, stays higher in its rear frame damper deflects in response to slow deflection range and helps to maintain speed impacts.
Page 39 Description SR SUNTOUR RS19-EDGE LOR8 TRUNNION Figure 10: SR SUNTOUR S19-EDGE LOR8 TRUNNION rear frame damper Air reservoir Specifications Rebound adjuster (rear frame damper) Air valve (rear frame damper) Suspension type Air suspension Overall length Damping LOR8 Settings while riding Damper unit O-ring Max.
Page 40 Description 3.5.2.3 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.5.2.4 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
Page 41 Description 3.5.2.6 Handlebars The pedelec is steered using the handlebars. The handlebars are used to support the upper body and are used to mount operating and display components (see Section 3.4.1). Figure 14: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
Page 42 Description Parts of a suspension fork Figure 15: Parts of a suspension fork Fork steerer Tyre clearance Sag adjuster Fork crown Tyre height Deflection (suspension fork) Tyre passage width Damper side Quick release Side view Pitch Installation height Fork end (suspension fork) Offset Quick release axle Air suspension side...
Page 43 Description Suspension fork assembly groups A suspension fork can feature up to three different assembly groups: • Compression damper (blue) • Rebound damper (red) • Air suspension or steel spring (orange) Figure 17: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
Page 44 Description Lock The compression can be disabled in any A suspension system absorbs great deal of motor suspension fork. A suspension fork will then and muscle power during rides uphill or on behave like a rigid fork. optimally tarmacked roads. This increases energy consumption and reduces propulsion.
Page 45 Description The suspension fork also deflect quickly and The suspension fork responds instantly to the unhindered when hitting bumps and cushions the impact. The headset and handlebars rise slightly bump when placed at an optimum setting. when absorbing a bump (green line). Traction is retained (blue line).
Page 46 Description Compression dampers When optimally adjusted, the suspension fork counteracts deflection on hilly terrain, stays Compression dampers damp deflection higher in its deflection range and helps to maintain movements, i.e. compression loads. speed when riding on hilly terrain. The compression damper controls the The suspension fork deflects instantly unhindered compression stroke speed or the extent to which and absorbs bumps when the bike hits one.
Page 47 Description Low-speed damper A slow compression speed is generated in the suspension fork when riding over bumps. The low- The low-speed damper (also abbreviated to LSC speed damper controls the suspension fork's from low-speed compression) is a specialised behaviour positively in such riding situations. compression damper.
Page 48 Description SR SUNTOUR cartridge function chart Compression damping setting Rebound damping setting Lockout Lockout High- Low- High- Low- Blow-off Remote Fork head speed speed Fixed speed speed Fixed feature control R2C2-PCS RC2-PCS RC-PCS RLRC-PCS LORC-PCS R2C2 RLRC LORC MY24K12 - 13_1.0_01.02.2024...
Page 49 Description 3.5.2.8 SR SUNTOUR 2CR-PCS The Suntour 3CR-PCS cartridge features a PCS damper platform with • a low-speed compression damper • a rebound damper Floating pistons within the PCS cartridge provide consistent damping on all driving surfaces through minimal cavitation (formation and dissolution of bubbles by mixing air and oil).
Page 50 Description 3.5.2.9 SR SUNTOUR cartridge LOR The SR Suntour LOR cartridge features • a low-speed compression damper 2. 2. • a low-speed rebound damper Before riding, use the rebound adjuster (suspension fork) (1) to adjust the system to the surface you will ride on. The suspension system can be adjusted to the current surface during rides using the low-speed compression adjustment wheel (2).
Page 51: Wheel
Description 3.5.3 Wheel Tyre pressure The permitted pressure range is indicated on the side of the tyre. It is indicated in psi or bars. The tyre is only able to support the pedelec if there is adequate tyre pressure. The tyre pressure must be adjusted to the body weight and then checked on a regular basis.
Page 52 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 53 Description Bead core 3.5.3.3 Rim The rim is the metal profile on a wheel which holds Tyre carcasses are wrapped around bead cores. the tyre, tube and rim band together. The rim is Wrapping the carcass around both sides creates joined to the hub with spokes.
Page 54 Description Presta valve 3.5.3.6 Spoke nipples The Presta valve, also known as the Sclaverand Spoke nipples are screw elements with an internal valve or the French valve, is the narrowest variant thread which fits onto the spoke thread. Fitted of all valves. The Presta valve requires a smaller spokes are tensioned by tightening the spoke hole in the rim, which is why it is especially nipples.
Page 55 Description 3.5.3.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.
Page 56: Brake
Description 3.5.4 Brake 3.5.4.2 Hydraulic brake A pedelec’s brake system is primarily operated using the brake lever on the handlebars. The brake fluid is in a closed hose system. If the brake lever is pulled, the brake fluid transfers • If the left brake lever is pulled, the brake on the front wheel is applied.
Page 57 Description 3.5.4.3 Disc brake Figure 38: 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 58 Description 3.5.4.4 Back-pedal brake Figure 39: 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 59: Saddle
Description 3.5.5 Saddle The purpose of the saddle is to absorb body When riding, the rider's body weight is distributed weight, provide support and enable different riding between the pedals, the saddle and the positions. The shape of the saddle thus depends handlebars.
Page 60 Description 3.5.5.1 Ladies’ saddle 3.5.5.2 Men’s saddle The distance between the ischial tuberosities and In contrast to the female anatomy, men's pubic the pubic symphysis is on average a quarter less bones are at a much steeper angle to one another. in women than in men.
Page 61: Seat Post
Description 3.5.6 Seat post Seat posts are not designed to fasten the saddle but also to adjust exactly to the optimum sitting position. The seat post can: • adjust the seat height in the seat tube • adjust the saddle horizontally with a clamping mechanism and •...
Page 62 Description 3.5.6.3 Structure of LIMOTEC, A1 The LIMOTEC A1 seat post is a continuously height-adjustable seat post. The remote control on the handlebars lowers the seat post. This can be used to adjust the saddle height during a ride, e.g. when stopped at traffic lights.
Page 63 Description 3.5.6.4 Structure of LIMOTEC A3 dropper post The LIMOTEC Alpha 3 suspension seat post is a The suspension in the seat post ensures sitting continuously height-adjustable seat post, which comfort when riding over rough terrain (e.g. in can be lowered using a remote control on the woodland or on farm tracks).
Page 64: Pinion Electric Drive System
Description 3.5.7 PINION electric drive system The pedelec has an electric drive system in The pedelec does not have a separate emergency addition to a mechanical one. shut-off button. In the event of an emergency, the motor can be stopped by removing the on-board computer.
Page 65 Description 3.5.7.5 FIT Remote Basic on-board computer The pedelec features a FIT Remote Basic on- Display board computer, which serves as a control panel. The on-board computer can be used with two The control panel on the handlebars uses 6 different displays.
Page 66: Control Panel
Description 3.5.8 Control panel The on-board computer is operated using six buttons on the control panel. Figure 53: Overview of the BOSCH control panel On-Off button (control panel) Navigation rocker switch Plus key Minus key Push assist button Light button MY24K12 - 13_1.0_01.02.2024...
Page 67: Handlebars With Fit Remote Basic With Fit Comfort Or Fit Compact Display
Description 3.5.9 Handlebars with FIT Remote Basic with FIT Comfort or FIT Compact display Figure 54: Detailed view of handlebars with FIT Remote Basic on-board computer and Compact 2.0 display, as example Rear wheel hand brake (behind handlebars) FIT Remote Basic on-board computer Bell Air valve FIT Comfort 2.0 display...
Page 68: Description Of Controls And Screens
Description Description of controls and screens 3.6.1 Display 3.6.1 .1 D RIV E MA IN ME NU The D RIV E MA IN ME N U screen will appear as soon as the display is switched on. The DRIVE M AIN M E NU has six indicator elements which are the same for all screens.
Page 69 Description 4. Level of assistance indicator B. Motor power indicator The higher the level of assistance is, the more the The motor power used is displayed as a bar. The drive system assists the rider when pedalling. maximum motor power depends on the selected level of assistance.
Page 70 Description 3. 6. 1 .3 T OU R MA IN ME NU 3.6.1 .4 T OU R S U B- ME NU 1 The indicator elements in the TO U R MA IN The indicator elements in the TOU R MA IN S UB - ME N U are the same as those in the DRIVE MAIN ME N U 1 are the same as those in the DRIVE MENU.
Page 71 Description 3. 6. 1 .5 T OU R S UB- ME NU 2 3.6.1 .6 F ITN E S S M A IN ME N U The indicator elements in the TOUR MA IN S UB - The indicator elements in the FIT NES S MA IN ME N U 2 are the same as those in the DRIVE ME N U are the same as those in the DRIVE MAIN MAIN MENU.
Page 72 Description 3. 6. 1 .7 F ITNE S S S UB -M EN U 3.6.1 .8 A RE A MA IN ME NU The indicator elements in the FIT NE SS S UB - The indicator elements in the A REA M AIN ME N U are the same as those in the DRIVE MAIN ME N U are the same as those in the DRIVE MAIN MENU.
Page 73 Description 3. 6. 1 .9 A RE A SU B -M ENU 3.6.1 .10 S ET TING S M ENU The indicator elements in the ARE A S UB -ME NU All system and service-relevant values can be are the same as those in the DRIVE MAIN MENU. read and changed in the settings.
Page 74 Description → • Default settings <Calibration Altitude> Changes the display settings. Calibrates the altimeter. Altitude → <Language> measurement depends on the air pressure and deviations may arise if the air pressure Set language. fluctuates. → <Time> → <Auto Backlight> Sets the clock. This allows you to select between the display screen backlight adjusted to the ambient light →...
Page 75 Description 3.6.1.11 System message The drive system monitors itself continuously and if an error is detected, it is indicated by a system message. The system may switch off automatically depending on the type of error. You will find assistance for system messages in Section 8.
Page 76: Handbrake
Description 3.6.2 Handbrake There is a handbrake on the left and right of the handlebars. Figure 66: 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 77: Gear Shift
Description 3.6.3 Gear shift 3.6.3.1 Pinion, E-Trigger TE1 Only applies to vehicles with this equipment PRE.SELECT Figure 67: Parts of Pinion E-Trigger TE1 Ring clamp with screw PRE.SELECT can be activated by selecting the Connector <Shift> menu in the settings on the on-board Screw-on position with blind screw computer.
Page 78: 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 79: Suspension And Damping On Rear Frame Damper
Description 3.6.5 Suspension and damping on rear frame damper Only applies to vehicles with this equipment 3.6.5.1 SR SUNTOUR Explanation Compression lever Blue operating element Rebound adjuster Red operating element Model Three rebound adjuster Two rebound adjuster Low-speed compression Low-speed rebound positions positions lever and low-speed rebound...
Page 80 Description Model R-3CR R-2CR RLR/RLR8 LOR/LOR8 Remote lock with three Remote lock with two RLR: LOR: Low-speed rebound rebound adjuster positions: rebound adjuster positions: Remote lock with rebound damper with two • lock • lock adjuster compression lever RLR8 positions: •...
Page 81 Description 3.6.5.2 FIT Supertube Indicators on the battery The five LEDs on battery level indicator show the charge level when the battery is switched on. Each LED represents 20% of the battery level. 100 … 80% 79 … 60% 59 … 40% 39 …...
Page 82: Transporting And Storing
Transporting and storing Transporting and storing Transportation 4.1.2 Transporting the pedelec Lithium-ion batteries store great amounts of energy. You must comply with a few precautionary CAUTION measures when transporting gas cylinders.  Discharge the battery to about 30% before Crash caused by unintentional activation placing pedelec in a vehicle to transport or take There is a risk of injury if the electric drive system it on a trip.
Page 83: Shipping A Pedelec
Transporting and storing 4.1.3 Shipping a pedelec 4.1.2.3 By local transport You can normally take pedelecs on local public  Private users are not permitted to ship transport, e.g. by bus or suburban rail, if you rechargeable batteries, neither by road not by purchase a bike ticket.
Page 84: Storing
Transporting and storing Storing  Remove the on-board computer from its mount  Store pedelec, on-board computer, battery and if the pedelec is not going to be used for up to charger in a clean, dry place where they are four weeks.
Page 85: Assembly 5.1 Unpacking
Assembly Assembly Scope of delivery WARNING 1 × pre-assembled pedelec  Risk of eye injury 1 × front wheel  Problems may arise if components are set 2 × pedals  incorrectly. They may cause serious injuries to 2 × quick releases (optional) ...
Page 86: 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 87: Adjusting The Limotec Seat Post
Assembly 5.3.2 Adjusting the LIMOTEC seat post Only applies to pedelecs with this equipment The rider’s body weight exceeds or falls below the  seat post’s functional weight. 1 Order new Limotec seat post with suitable functional weight. 2 Remove existing seat post. Replacing Limotec A1 and A5 3 Use the seat height formula to calculate the optimum seat post height for leg length:...
Page 88: 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 89: 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 90 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 91 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 81: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 92 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 93: Fitting The Pedals
Assembly 5.3.5 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.
Page 94: Checking The Stem And Handlebars
Assembly 5.3.6 Checking the stem and handlebars 5.3.6.1 Checking the connections 5.3.6.3 Checking the bearing clearance 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.
Page 95: 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 96 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 97: 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 98: 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 99: Riding Position
Operation 6.4.2 Riding position The starting point for a comfortable posture is the The pelvis is positioned incorrectly if it tilts slightly correct position of the pelvis. If the pelvis is in the backwards. As a result, the spine becomes curved wrong position, it can cause different types of and can no longer deflect to an optimal extent.
Page 100 Operation Position on roadster Position on city bike Position on trekking Position on sports bike bike Upright, almost vertical Slightly inclined upper Sharply inclined upper Greatly inclined upper posture, body, body, body, back at an angle back at an angle of back at an angle of back at an angle of Angle of upper body...
Page 101: 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 102 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 92: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
Page 103 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 104 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 105 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 106 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 107 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 108: 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 109 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 110: 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 111 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 112: 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 113: Tyres
Operation 6.4.8 Tyres 6.4.8.1 Replacing tyres As a general rule, wide tyres are operated at a lower tyre pressure. They provide the option of Not included in price exploiting the advantages of the lower tyre pressure without the serious disadvantages it Different tyres need to be used when the area of causes with regard to wear, rolling resistance and §...
Page 114 Operation 2 Perform a visual check on tyres. Figure 113: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 114: Far too little tyre pressure MY24K12 - 13_1.0_01.02.2024...
Page 115: 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 116 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 117 Operation 6.4.9.6 MAGURA handbrake pressure point Only applies to pedelecs with this equipment The pressure point setting is adjusted using the twist knob. WARNING  Turn the twist knob towards the plus (+) Brake failure due to incorrect setting symbol. If the pressure point is set with brakes where the ...
Page 118 Operation 6.4.9.7 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 119: 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 120: 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 121 Operation 6.4.12.1 Adjusting the sag for SR SUNTOUR air suspension fork Only applies to pedelecs with this equipment 1 Turn the air valve cap (see Section 3.6.4.1) 3 Pump air suspension to the required pressure anti-clockwise away from the air valve level.
Page 122 Operation Recommended air pressure [psi] < 55 40… 55 40… 55 40… 55 40… 55 40… 55 40… 55 55… 65 … … 55… 65 55… 65 55… 65 55… 65 65… 75 … … 65… 75 65… 75 65… 75 65…...
Page 123 Operation Adjusting preload internally  Only your specialist dealer may make an internal adjustment to the preload. The air volume spacers can be replaced on some fork models. This changes the value for the centre stroke and the bottom-out (bounce) resistance. ...
Page 124 Operation Aion35 Zeron35 Axon32 Mobie34-air Mobie45-air Rubber volume 4.3cc 4.3cc space Deflection [mm] … … … … … … … … … … … … … … … … … … … … … … … … … … … …...
Page 125 Operation 6.4.12.2 Adjusting the sag for the SR SUNTOUR steel suspension fork Only applies to pedelecs with this equipment You can pre-tension the steel suspension to riding style. It is not the coil spring hardness which adjust to the rider's weight and their preferred is adjusted;...
Page 126: 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 127 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 128 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 41: Recommended sag for the rear frame damper 14 The air pressure must be adjusted if the required sag level is not reached.
Page 129 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 130: Adjusting The Suspension Fork Rebound Damper
Operation 6.4.14 Adjusting the suspension fork rebound damper Only applies to pedelecs with this equipment Rebound damping is adjusted to the rider’s body weight, spring stiffness, deflection, the terrain and the pedelec rider's preferences. If the air pressure or spring stiffness increases, the extension and rebound speeds also increase.
Page 131 Operation 6.4.14.1 Adjusting the SR Suntour rebound damper suspension fork Only applies to pedelecs with this equipment Figure 125: Example of SR SUNTOUR rebound adjuster (suspension fork) (1) Adjusting the suspension fork sag (see  Section 6.4.12). 1 Turn the rebound adjuster (suspension fork) clockwise to the closed position until it stops.
Page 132: Adjusting The Rear Frame Damper Rebound Damper
Operation 6.4.15 Adjusting the rear frame damper rebound damper Only applies to pedelecs with this equipment Adjust the rebound damper so that the rear frame damper rebounds quickly but without bottoming out upwards. Bottoming out refers to occasions when the rear frame damper rebounds too quickly and stops moving abruptly once it has reached the full rebound distance.
Page 133 Operation 6.4.15.1 Adjusting the SR Suntour rear frame damper rebound damper Only applies to pedelecs with this equipment Figure 126: Position of SR Suntour rebound adjuster (rear frame damper) on rear frame damper Triair2 (a), Triair (b), EDGE- comp (c), EDGE (d) and RAIDON (e) ...
Page 134: Adjusting The Rear Frame Damper Compression Damper
Operation 6.4.16 Adjusting the rear frame damper compression damper When optimally adjusted, the rear frame damper deflects quickly and unhindered when the bike hits bumps and absorbs a bump. Traction is retained (blue line). The saddle rises slightly when absorbing a bump (green line). Compression adjuster set to hard Compression adjuster set to soft •...
Page 135 Operation 6.4.16.1 Adjusting the Suntour compression damper with continuously variable compression adjuster Only applies to pedelecs with this equipment  Turn compression adjuster clockwise.  The damping and compression hardness is increased. The deflection stroke speed is reduced. very This setting is ideal for terrain with uneven surfaces and large edge bumps.
Page 136: Riding Light
Operation 6.4.17 Riding light 6.4.17.1 Replacing the headlight 6.4.17.2 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 137 Operation 6.4.17.4 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 138: Adjusting The On-Board Computer And Fit Compact
Operation 6.4.18 Adjusting the on-board computer and FIT Compact 6.4.18.2 Securing the display CAUTION It is possible to secure the display in its mount so that it cannot be removed. Crash caused by distraction A lack of concentration while riding increases the risk of an accident.
Page 139 Operation 6.4.18.4 Operating the display 6.4.18.6 Opening other menus The display is operated using six buttons on the  Press the navigations button to the left or control panel. right.  A new menu is displayed. 6.4.18.7 Changing the settings The pedelec is stationary.
Page 140 Operation Adjusting units Menu Submenu The displayed units can be shown using the metric → <Charge to Storage> or imperial system. The unit can be selected from → <LONG-LIFE mode> the following variables: Errors Variable Metric Imperial About Distance Table 42: Basic structure of FIT menu and sub-menu Speed km/h Setting the language...
Page 141 Operation Connecting the Komoot app Calibrating the altimeter The Komoot app can be connected to the FIT The altimeter can be calibrated. system. More information at: www.komoot.com/ 1 Open the S E TT INGS ME NU. 1 Open the S E TT INGS ME NU. 2 Open <My Bike><Calibration Altitude>.
Page 142 Operation Setting the vibration feedback Resetting all tour data The vibration feedback can be adjusted. All values in the TOUR MAIN MENU and SUB- MENU can be reset. 1 Open the S E TT INGS ME NU. • Trip 2 Open <My Bike><Vibration feedback>. •...
Page 143: Accessories
Only applies to pedelecs with this equipment CAUTION Only compatible bicycle trailers are approved for ENVIOLO hub gears. Crash caused by brake failure KETTLER trailers The braking distance may be longer if the trailer is carrying excessive load. The long braking • Quadriga Child Trailer distance can cause a crash or an accident and •...
Page 144  Never fit a trailer hitch directly on the axle and Grey/light blue the A-12 attachment screw to a ROHLOFF 08948-520 08948-530 Child trailer Speedhub with an A-12 axle system in a Grey/black 12 mm quick release axle frame. More information at: https://www.kettler-alu-rad.de/gb-en/accessories MY24K12 - 13_1.0_01.02.2024...
Page 145 • Dimensions: 800 x 500× 800 mm (L × W × H) • Assembled without tools More information at: • Ventilation net at the front and rear https://www.kettler-alu-rad.de/gb-en/accessories • Zip entry • Cover made of water-repellent nylon Article number Description...
Page 146: Child Seat
Risk of crushing due to exposed springs More information at: The child may crush his/her fingers on exposed https://www.kettler-alu-rad.de/gb-en/accessories springs or open mechanical parts of the saddle or the seat post.  Never install saddles with exposed springs if a child seat is being used.
Page 147 Adjustable foot rests and foot straps • Integrated reflector Article number Description 08948-420 Quadriga child seat Black/black 08948-430 Quadriga child seat Black/blue 08948-440 Quadriga child seat Black/light blue 08948-410 Quadriga child seat Black/lime More information at: https://www.kettler-alu-rad.de/gb-en/accessories MY24K12 - 13_1.0_01.02.2024...
Page 148: Monkeyload System
08949-960 Smartbag One4all Multifunctional pannier rack bag with shoulder strap More information at: Figure 143: Basket with MonkeyLoad adapter plate and https://www.kettler-alu-rad.de/gb-en/accessories pull knob (1) 6.5.4 Front baskets 6.5.3.1 Attaching MonkeyLoad system components Take care with front baskets because their load §...
Page 149: Panniers And Cargo Boxes
Use on tarmacked roads only. Protect mobile from theft.  More information at: https://www.kettler-alu-rad.de/gb-en/accessories 6.5.6.1 Fastening the mobile 1 To attach, place the mobile which is in an SP 6.5.5.2 Quadriga Front & Rear Basket Connect mobile case onto the phone case.
Page 150: Suspension Fork Coil Spring
Operation 6.5.6.2 Releasing the mobile 6.5.11 Kickstand 1 Turn the mobile 90° to the left Kickstands are permitted if they are able to bear § the weight of the pedelec.  The fastener is released. 2 Remove mobile We recommend a parking stand into which either the front wheel or rear wheel can be inserted 6.5.7 Suspension fork coil spring...
Page 151: 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 152: Straightening The Quickly Adjustable Stem
Operation Straightening the quickly Using the pannier rack adjustable stem CAUTION Only applies to pedelecs with this equipment 1 Open stem clamping lever. Crash caused by loaded pannier rack The pedelec is handled differently with a loaded pannier rack, in particular when the rider needs to steer and brake.
Page 153: Raising The Kickstand
Operation 6.11.1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the leather to dry out and fade.  Park pedelec in the shade.  Always use a saddle cover. Moisture may cause the leather to detach from material beneath and mould may form.
Page 154: Setting The Saddle Height With The Remote Control
Operation 6.13 Setting the saddle height with the 6.15 Using the handlebars remote control  Wear heavily padded cycling gloves. Only applies to pedelecs with this equipment  This helps protect sensitive areas of your palms. 6.13.1 Lowering the saddle ...
Page 155: Using Bar Ends
Operation 6.15.2 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 156: Adjusting The Rear Frame Damper
Operation 6.15.4 Adjusting the rear frame damper  Before each ride, adjust the suspension and/or damping to the terrain if you have a rear frame damper. Terrain Position Suspension Setting off Open Uphill or tarmacked roads Lock out Energy saved while riding on roads and/or for Threshold maximum pedalling efficiency on flat or smooth terrain...
Page 157: Adjusting The Rear Frame Damper Compression Damper
Operation 6.15.5 Adjusting the rear frame damper compression damper When optimally adjusted, the rear frame damper The saddle rises slightly when absorbing a bump deflects quickly and unhindered when the bike hits (green line). bumps and absorbs a bump. Traction is retained The compression damper has two settings: (blue line).
Page 158 Operation 6.15.5.1 Adjusting the SR SUNTOUR rear frame damper 2C compression damper Only applies to pedelecs with this equipment damper circuit. As a result, the rear frame damper responds with maximum sensitivity to the ground. CAUTION The OPEN setting is suitable for light riders or for Crash caused by damaged rear frame damper dry, dusty terrain where maximum traction is The rear frame damper can be damaged if it is...
Page 159: Using The Supercore Battery
Operation 6.16 Using the SuperCore battery Switch off the battery and the drive system before removing or inserting the battery.  6.16.1 Removing the battery 6.16.2 Inserting the battery 1 Turn locking lever to right. 1 Place the battery into the lower mount with the contacts facing the front.
Page 160: Charging The Battery
Operation 6.16.3 Charging the battery The indicator shows the charge level during charging. CAUTION LED 1,2,3,4,5 Battery level Fire caused by overheated charger 100 - 80% The charger heats up when charging the battery. In case of insufficient cooling, this can result in 79 - 60% fire or burns to the hands.
Page 161: Electric Drive System
Operation 6.17 Electric drive system 6.17.1 Switching on the electric drive 6.17.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in normal mode or reaches a speed of 25 km/h, the CAUTION drive system switches off the assistance system.
Page 162: Control Panel
Operation 6.18 Control panel 6.18.1 Using the push assist system 3 Release the push assist button to switch off the push assist system. 4 Push assist mode switches off if the push CAUTION assist button is released for ten seconds. Push assist mode will also switch off Injury from pedals or wheels automatically if the speed exceeds 6 km/h.
Page 163: Selecting The Level Of Assistance
Operation 6.18.2 Selecting the level of assistance  The control panel is used to set how much the electric drive assists the rider when pedalling. You can change the level of assistance at any time, even when you are cycling. Figure 160: Position of plus button (1), minus button (2) and push assist button (3) ...
Page 164: Using Pinion Gears
Operation 6.18.3 Using Pinion gears Only applies to pedelecs with this equipment Pinion gears switch between 9 or 12 speeds. It is 6.18.3.1 Shifting gear with E-Trigger TE1 possible to switch between several gears in one shift action (e.g. from 06 to 02). Changing gear is possible when the crank is stationary or rotating backwards and is gentle on the gears.
Page 165: 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 166: Use Suspension And Damping
Operation 6.20 Use suspension and damping 6.20.1 Locking the suspension A suspension system is designed to cushion and Some suspension forks thus feature a lockout on compensate for unevenness on a surface whether the crown or a remote lockout activated on the the user is riding on bumpy cycle paths, dirt roads handlebars.
Page 167: Adjusting The Suspension Fork Compression Damper
Operation 6.20.2 Adjusting the suspension fork compression damper The compression damper allows the rider to make When placed at an optimum setting, the quick adjustments to the suspension behaviour of suspension fork counteracts deflection on hilly the suspension fork to adapt to changes in terrain. terrain, remains higher in its deflection range and It is intended for adjustments made during the helps maintain speed when riding on terrain hilly...
Page 168 Operation 6.20.2.1 Using SR Suntour high-speed compression damping A high speed is generated in the suspension fork, The settings on the high-speed damper control e.g. on a mogul slope or during landing after a the suspension behaviour of the fork during jump.
Page 169 Operation 6.20.2.2 Using the SR Suntour low-speed compression damping Low-speed movement in the suspension fork is The settings on the high-speed damper control caused, for example, by riding over bumps. the suspension behaviour of the fork • during staggered jumps •...
Page 170: Parking
Operation 6.21 Parking 6 Remove battery to protect against theft (see Notice Section 6.7.1.1). 7 Clean and service pedelec after every ride; see Heat or direct sunlight can cause the tyre pressure Section 7.2. to increase above the permitted maximum pressure.
Page 171: Screwing In The Quickly Adjustable Stem
Operation 6.21.1 Screwing in the quickly adjustable 6.21.2 Folding up the pedal stem  Clean the pedal (see Section 7.2.4). Only applies to pedelecs with this equipment 1 Use two fingers to pull the pedal folding latch (1) Screw in the quickly adjustable stem to save downwards and hold in position.
Page 172: 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 173 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 174 Cleaning, maintenance and inspection Checklist: Tasks performed at least every six months Checklist: Tasks performed at least every six months (or every 1,000 km) (or every 1,000 km) Check Bowden cables gear Servicing the stem See Section 7.4.6   See Section 7.5.10.2 shift...
Page 175 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 176: 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 177: 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 178: 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 179: 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 180: 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 181: 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 182: 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 183: 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 184: 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 185: 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 186: 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 187: 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 188: 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 189: 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 190: 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 191 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 192 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 193 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 194: 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 195 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 196 Cleaning, maintenance and inspection 7.5.2.5 Checking the back-pedal brake Only applies to pedelecs with this equipment There are sharp corners and edges on the back-  pedal brake. Wear gloves. 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube.
Page 197: Checking The Belt
Cleaning, maintenance and inspection 7.5.3 Checking the belt  The tooth profile is pointed and teeth have worn thinner. Contact specialist dealer. The belt sprocket does need to be replaced. 7.5.3.1 Checking the belt for wear  Check belt for indications of wear: Figure 177: Indications of wear on a belt Figure 179: Worn tooth profile 1 Carbon tensile fibres are exposed...
Page 198 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 199 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 183: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.
Page 200: Checking The Riding Light
Cleaning, maintenance and inspection 7.5.4 Checking the riding light 1 Check the cable connections on the headlight  If the headlight or rear lights do not come on, take pedelec out of service. Contact specialist and rear light for damage and corrosion and dealer.
Page 201: Checking The Stem
Cleaning, maintenance and inspection 7.5.5 Checking the stem 7.5.8 Checking the seat post 1 Take seat post out of the frame.  The stem and quick release system must be 2 Check seat post for cracks and corrosion. inspected at regular intervals. The specialist dealer should adjust them if they require 3 Reinsert seat post.
Page 202: Checking The Gear Shift
Cleaning, maintenance and inspection 7.5.10 Checking the gear shift 4 Check that there is clearance between the chain tensioner and spokes. 1 Check that all gear shift components are free of  If there is no clearance or the chain scrapes damage.
Page 203 Cleaning, maintenance and inspection 7.5.10.5 Adjusting the ROHLOFF hub 7.5.10.6 Adjusting the cable-operated gear shift, dual-cable Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment 1 Check whether shift cable tension is set in such ...
Page 204 Cleaning, maintenance and inspection 7.5.10.8 Checking kickstand stability 1 Place the pedelec on a slight elevation of 5 cm. 2 Extend kickstand. 3 Jolt pedelec to check stability.  If pedelec topples over, tighten screws or change height of the kickstand. MY24K12 - 13_1.0_01.02.2024...
Page 205: 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. The tasks require technical Vibrations produced while riding can cause expertise, special tools and special lubricants. screws and springs that were tightened during The pedelec may become damaged if the pedelec manufacture to settle or come loose.
Page 206 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 207 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 208: Carrying 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 209: 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 210 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.5 O.K. Dirt Cleaning month 6 months … Section 7.4.6 O.K. Untreated Stem 6 months Check mount fas- Section 7.5.5 …...
Page 211 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 212 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 213 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 214 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 215 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 216: 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 217: 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 218: 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 219: 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 220: 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 221 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 222: Torque
Description 8.5.10 Torque Model Torque Tool Axle Conventional axle nut 35 … 40 Nm* 15 mm spanner SR SUNTOUR screw-on axle 12AH2 Axle 8 … 10 Nm 6 mm hex bit Securing screw 5 … 6 Nm 5 mm hex bit SR SUNTOUR screw-on axle 15AH2 Axle...
Page 223 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 Slotted-head screwdriver TEKTRO for hydraulic disc brake system...
Page 224 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 225 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 226 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 227 Description SHIMANO, FC-M8000, single version Attachment screw for crank/ chainring 12 … 14 Nm Star bit [no. 30] SHIMANO, FC-M8000, dual version Largest chainring 12 … 14 Nm Star bit [no. 30] Smallest chainring 16 … 17 Nm Star bit [no. 30] SHIMANO, FC-M8000, triple version Largest chainring...
Page 228 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 229 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 230 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 231 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 232 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 233: Troubleshooting, Fault Clearance And Repair
Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair 10.1 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 234: Sitting Discomfort
Troubleshooting, fault clearance and repair 10.1.1 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 235: Pain In Shoulders And Nape Of Neck
Troubleshooting, fault clearance and repair 10.1.4 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 236: Knee Pain
Troubleshooting, fault clearance and repair 10.1.7 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 237: Fit Drive System
Troubleshooting, fault clearance and repair 10.2 FIT drive system The components of the drive system are checked 7 Insert the battery. constantly and automatically. If an error is 8 Start the drive system. detected, an error message appears on the 9 If the drive system does not start up, remove display.
Page 238: Battery Error
Troubleshooting, fault clearance and repair Symptom Cause Remedy The battery does not perform as well in This does not indicate a problem. winter weather. The journey distance can be shorter 11 Check battery is charged. depending on the road conditions, the gear level and the entire light usage 12 Recharge the battery if it is almost flat.
Page 239 Troubleshooting, fault clearance and repair Symptom Cause Remedy 32 Interrupt charging process. 33 Wait a moment. The battery or charger temperature The battery and charger may have exceeded the operating 34 Start charging. become hot. temperature range. 35 If the battery is too hot to touch, there might be a problem with the battery.
Page 240: Pinion Error Message
Troubleshooting, fault clearance and repair 10.2.5 PINION error message 10.2.5.1 Display Warnings The drive system monitors itself continuously and Hazardous situations are indicated with warning indicates a known hazard with a warning symbol symbols on the display screen. or displays a number as an error message if a Symbol Description Method of resolution...
Page 241 Troubleshooting, fault clearance and repair Error messages Code Description Method of resolution 0A-0A, Remote-Charger Restart system. 0B-0A Communication Error Switch off system. Disconnect charger from system and socket. Wait until the status LED goes out. Check plug contacts on pedelec and charger and clean if necessary.
Page 242 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 0C-0A Remote-Charger Restart system. 0D-0A Charger Authenti- Restart system. Identification Error cation Error Switch off system. Switch off system. Disconnect charger from Disconnect charger from system and socket.
Page 243 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 0F-07 Speednode Update Restart system. 12-03, Remote-Battery Switch off system. Error 12-04, Pairing-Error Contact your specialist Remove battery from 12-05, dealer if the problem 12-06 mount.
Page 244 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 15-02 Remote-Display Restart system. 16-01 Motor Theft Detection Restart system. Pairing Error Switch off system. Contact your specialist dealer if the problem Remove display from persists.
Page 245 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 16-0B Lock Theft Detection Restart system. 17-0B Lock Defective Restart system. Component Contact your specialist Contact your specialist dealer if the problem dealer if the problem persists.
Page 246 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 18-0B Lock Start Error Restart system. 21-xx Lock Error Start system. Contact your specialist Contact your specialist dealer if the problem dealer if the problem persists.
Page 247 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution Display Software Error 1 2A-xx Restart system. 49-09, Motor Unit Error Check if one or both 49-0A trigger buttons are being Switch off system. held down. If so, release Remove display from buttons.
Page 248 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 4D-03 Gear Shift Error Relieve pressure on 51-01 Motor Voltage Error Start system. Relieve pressure on 51-02 Battery Voltage Error pedals so that the Check lighting and its pedals pedelec can switch to cabling for damage.
Page 249 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 68-0B Battery Current Error Switch off system. 69-05, Battery Temperature Switch off system. 68-13 Overcurrent Error 69-0A, Error Remove the battery. Leave battery to cool 69-0F, 69-11, down (>...
Page 250 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 6D-xx Unknown Battery Check that the correct 97-xx Charger Check that the correct Error Charging Current battery has been battery has been Error inserted (36 V/48 V). inserted (36 V/48 V).
Page 251 Troubleshooting, fault clearance and repair 10.2.5.2 UltraCore battery Description Method of resolution In the event of a hazard, a protective circuit Code: switches the battery off automatically. If a battery fault is detected, the LEDs on the Charge Level indicator will flash. Temperature error Check the battery An authentication error may...
Page 252: Correcting Disc Brake Faults
Troubleshooting, fault clearance and repair 10.2.6 Correcting disc brake faults Symptom Cause Remedy Ringing and unusual  Contact specialist dealer. Fit a city or trekking tyre. sounds from disc brakes. Riding on asphalt with off-road tyres. Dirty or greasy brake disc. ...
Page 253: Problems With Back-Pedal Brake
Troubleshooting, fault clearance and repair 10.2.7 Problems with back-pedal brake Symptom Cause Remedy Contact specialist dealer. Lubricate brake hub. Brake is too sensitive Replace brake shoe unit. Contact specialist dealer. Replace brake shoe unit. Brake is too weak If the problem should persist, replace the internal hub unit. The rider needs to push Contact specialist dealer.
Page 254: Correcting Faults In The Sr Suntour Suspension Fork
Troubleshooting, fault clearance and repair 10.2.8 Correcting faults in the SR SUNTOUR suspension fork 10.2.8.1 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 255 Troubleshooting, fault clearance and repair 10.2.8.2 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 256 Troubleshooting, fault clearance and repair 10.2.8.3 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 203: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
Page 257 Troubleshooting, fault clearance and repair 10.2.8.4 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 258: Correcting Faults In The Sr Suntour Rear Frame Damper
Troubleshooting, fault clearance and repair 10.2.9 Correcting faults in the SR SUNTOUR rear frame damper 10.2.9.1 Rebound too fast The rear frame damper rebounds too quickly, Saddle and handlebars are deflected upwards producing a "pogo stick" effect or causing the bike when the wheel bounces back from the ground.
Page 259 Troubleshooting, fault clearance and repair 10.2.9.2 Rebounding too slowly The rear frame damper does not rebound quickly The rear frame damper remains in a deflected enough after a bump has been compensated and state after contact with the first bump. When the is not in the required initial position when the rear wheel hits the second bump, the saddle wheel hits the next bump.
Page 260 Troubleshooting, fault clearance and repair 10.2.9.3 Suspension too soft on inclines The rear frame damper deflects deeply through used up, body weight shifts downwards and the the deflection range. The deflection is quickly pedelec loses some momentum. Figure 209: Excessively soft suspension in the rear frame damper on hilly terrain Solution ...
Page 261 Troubleshooting, fault clearance and repair 10.2.9.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.
Page 262: Correcting Freewheel Faults
Troubleshooting, fault clearance and repair 10.2.10 Correcting freewheel faults Symptom Cause Remedy Cover forgotten after fitting.  Contact specialist dealer. Check installation correct. Freewheel blocked.  Contact specialist dealer. Measure the length of the socket. If After fitting, socket was compressed by over-tightening the quick-release axle.
Page 263: Correcting Lighting Faults
Troubleshooting, fault clearance and repair 10.2.11 Correcting lighting faults Symptom Cause Remedy The front light or rear light The default settings in the electric drive Take pedelec out of service immediately. does not go on, even system have probably been configured when the switch is Contact specialist dealer.
Page 264: Correcting Other Faults And Errors
Troubleshooting, fault clearance and repair 10.2.14 Correcting other faults and errors Symptom Cause Remedy Two beeps will sound if a Pressed switch mode has been  This is not a malfunction. switch is pressed but the deactivated. switch cannot be operated.
Page 265: Repairs At The Specialist Dealer
Troubleshooting, fault clearance and repair 10.3 Repairs at the specialist dealer 10.3.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 10.3.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...
Page 266: Replacing The Riding Light
Troubleshooting, fault clearance and repair 10.3.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 10.3.5 Adjusting the headlight  The headlight must be positioned so that its light beam shines on the road 10 m in front of the pedelec (see Section 6.4).
Page 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 MY24K12 - 13_1.0_01.02.2024...
Page 275: 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 276 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 277 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 278: 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 279: Appendix
Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications – Part 2: Lithium systems. Cologne, 20.10.2023 ……………………………………………………………………………………………… Egbert Hageböck, Managing Director of KETTLER Alu-Rad GmbH * Community member who is authorised to compile the technical documentation MY24K12 - 13_1.0_01.02.2024...
Page 280: Keyword Index
Keyword index Keyword index Brake calliper, 57 CE marking, 275 position, 57 Chain guard 16 Air valve, 43 torque, 223 Chain guard, position, 43 Brake disc, 57 - clean, 183 Articulated shaft, - check, 195 torques 227 - maintain 187 - clean 182 Chain stay, 34 Axle,...
Page 281 Keyword index Down tube, 34 Gear shift, Drive belt, 275 - adjust dual-cable, Bowden- Initial commissioning, 86 Drive system, cable-operated twist grip - switch on, 162, 163 shifter 203 Jockey wheel, - switching on, 161 - check 202 - maintain 187 electric, 64 - check electric gear shift, Dual pivot rim brake,...
Page 282 Keyword index Mudguard, - service 184 Reflectors, - clean, 180 - ship, 83 - clean 178 - maintain, 185 - store, 84 Riding light Mudguards, - transport, 82 - switch on 162 - check, 176 - unpacking 85 Riding light, - use 152 - adjust, 137 Placing on the market, 277...
Page 283 Keyword index Shifter, Tyre size, 51 - clean, 182 Tyre, - maintain, 187 position, 51 position, 67 Tyres, 51 torque, 230 - check, 192 Shut-off speed, 277 - clean 181 Size, 34 Tyres,- Tube-type tyres 51 Slicks, 52 Slippage, 277 Underride guard, Spare part, 277 torque, 232...

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