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TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
MY21B01 - 12_1.0_04.05.2020
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
KM/H
AMM
P MWH
MIN
MPH
KM
/H
BULLS Cross Mover Evo 1, BULLS Cross Mover Evo 2 , BULLS Cro ss Ride r Evo 1 (Münch en),
BULL S Cross Ri der Evo 2 (Cologn e), BUL LS Cross Street E1
21-15-1016 - 21-15-1018, 21-15-1027, 21-15-1028, 21-15-1069, 21-15-1070, 21-17-1013 - 21-17-1015,
21-17-1029 - 21-17-1030, 21-17-1045, 21-17-1064
MY21B01 - 12_1.0_06.07.2020 2
Contents
Contents
1 About these operating instructions 6
1.1 Manufacturer 6
1.2 Language 6
1.3 Laws, standards and directives 6
1.4 For your information 6
1.4.1 Warnings 6
1.4.2 Markups 7
1.5 Nameplate 8
1.6 Type number and model 9
1.7 Identifying the operating instructions 9
2 Safety 10
2.1 Residual risks 10
2.1.1 Risk of battery fire and explosion 10
2.1.2 Risk of fire and explosion due to short
circuit in the battery 10
2.1.3 Fire hazard caused by overheated
charger 10
2.1.4 Electric shock caused by electric drive
system 10
2.1.5 Risk of a fall due to incorrectly set quick
releases 10
2.1.6 Risk of fire and burns due to hot motor 11
2.1.7 Key breaking off 11
2.2 Toxic substances 11
2.2.1 Brake fluid 11
2.2.2 Suspension oil 11
2.2.3 Defective battery 11
2.3 Requirements for the rider 11
2.4 Vulnerable groups 11
2.5 Personal protective equipment 11
2.6 Safety markings and safety instructions 11
2.7 What to do in an emergency 12
2.7.1 Dangerous situation in road traffic 12
2.7.2 Leaked brake fluid 12
2.7.3 Battery vapours emitted 13
2.7.4 Battery fire 13
2.7.5 Leaked brake fluid 13
2.7.6 Oil and lubricant leaks from the fork 13
2.7.7 Oil and lubricant leaks from the rear
frame damper 13
3Overview 14
3.1 Description 15
3.1.1 RANGE 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.2.1 Rigid fork 15
3.1.2.2 Suspension fork 15
3.1.2.3 Steel suspension fork 16
3.1.3 Brake system 16
3.1.3.1 Disc brake 16
3.1.4 Drive system 17
3.1.5 Rechargeable battery 17
3.1.5.1 Frame battery 18
3.1.5.2 Pannier rack battery 19
3.1.5.3 Integrated battery 19
3.1.6 Display 20
3.1.7 Control panel 20
3.1.7.1 USB port 20
3.1.8 Riding light 20
3.1.9 Charger 20
3.2 Proper use 21
3.2.1 Maximum permitted total weight 22
3.2.2 Data privacy information 22
3.3 Improper use 22
3.4 Proper use 23
3.5 Improper use 24
3.5.1 Maximum permitted total weight 25
3.5.2 Data privacy information 25
3.6 Environmental requirements 26
3.7 Technical data 28
3.7.1 Pedelec 28
3.7.2 Emissions 28
3.7.3 Tightening torque 28
3.7.4 Intuvia display 28
3.7.5 USB port 28
3.7.6 Active Line motor 28
3.7.7 Active Line Plus motor 28
3.7.8 Performance Line motor 29
3.7.9 Performance Line Cruise motor 29
3.7.10 Bicycle lighting 29
3.7.11 PowerPack 300 battery 29
3.7.12 PowerPack 400 battery 29
3.7.13 PowerPack 500 battery 29
3.7.14 PowerTube 400 battery 30
3.7.15 PowerTube 500 battery 30
3.7.16 PowerTube 625 battery 30
3.7.17 BOSCH pedelec ABS BAS100 30
3.8 Description of controls and screens 31
3.8.1 Handlebars 31
3.8.2 Rechargeable battery 31
3.8.3 Display 31
3.8.4 Control panel 31
3.8.5 On-screen indicators 32
3.8.5.1 Riding light indicator 32
3.8.5.2 Level of assistance indicator 32
3.8.5.3 Battery level indicator (display screen) 32
3.8.5.4 Indicator for motor power used 33
3.8.5.5 Gear recommendation indicator 33
3.8.5.6 Tachometer indicator 33
3.8.5.7 Function display 33
3.8.5.8 Journey information 33
MY21B01 - 12_1.0_06.07.2020 3
Contents
3.8.5.9 Additional journey information 33
3.8.5.10 System settings and data 34
3.8.5.11 Additional system settings 34
3.8.6 System message 35
3.8.7 ABS indicator lamp 35
4 Transporting and storing 36
4.1 Physical transport characteristics 36
4.1.1 Weight and dimensions during
transportation 36
4.1.2 Designated handles/lifting points 36
4.2 Transporting 36
4.3 Storing 36
4.3.1 Break in operation 37
4.3.1.1 Preparing a break in operation 37
4.3.1.2 Taking out of operation 37
5 Assembly 38
5.1 Required tools 38
5.2 Unpacking 38
5.2.1 Scope of delivery 38
5.3 Preparing the battery 38
5.3.1 Checking the battery 38
5.3.2 Retrofitting a PowerTube Adapter 400
or 500 38
5.4 Commissioning 40
5.4.1 Installing the wheel in the Suntour fork 40
5.4.1.1 Screw-on axle (15 mm) 40
5.4.1.2 Screw-on axle (20 mm) 41
5.4.1.3 Quick release axle 41
5.4.1.4 Quick release 43
5.4.2 Installing the wheel in the FOX fork 44
5.4.2.1 Quick release (15 mm) 44
5.4.2.2 Kabolt axle 45
5.4.3 Checking the stem and handlebars 45
5.4.3.1 Checking the connections 45
5.4.3.2 Firm hold 45
5.4.3.3 Checking the headset backlash 45
5.5 Pedelec sale 45
6 Operation 46
6.1 Risks and hazards 46
6.1.1 Personal protective equipment 47
6.2 Tips for a greater range 47
6.3 Error message 48
6.3.1 Display 48
6.3.2 Rechargeable battery 50
6.4 Instruction and customer service 51
6.5 Adjusting the pedelec 51
6.5.1 Adjusting the saddle 51
6.5.1.1 Adjusting the saddle tilt 51
6.5.1.2 Determining the seat height 51
6.5.1.3 Adjusting the seat height with quick
release 52
6.5.1.4 Adjusting the seat position 52
6.5.2 Adjusting the handlebars 53
6.5.3 Adjusting the stem 53
6.5.3.1 Adjusting the height of the handlebars 53
6.5.3.2 Adjusting the quick release clamping
force 53
6.5.4 Retracting the brake linings 53
6.5.5 Adjusting the Suntour fork 54
6.5.5.1 Adjusting the negative deflection 54
6.5.5.2 Adjusting the steel suspension fork
negative deflection 54
6.6 Accessories 55
6.6.1 Child seat 55
6.6.2 Trailer 56
6.6.3 Pannier rack 56
6.7 Check list before each ride 57
6.8 Using the kickstand 58
6.8.1 Raising the kickstand 58
6.8.1.1 Parking the pedelec 58
6.9 Using the pannier rack 58
6.10 Rechargeable battery 59
6.10.1.1 Removing the frame battery 59
6.10.2.1 Removing the pannier rack battery 59
6.10.4 Charging the battery 61
6.10.5 Charging the dual battery 61
6.10.5.1 Charging process when two batteries
are used 61
6.10.5.2 Charging process when one battery
is used 62
6.10.6 Using double battery model with a
single battery only 62
6.10.7 Waking the battery 62
6.11 Electric drive system 63
6.11.1 Switching on the electric drive system 63
6.11.2 Switching off the drive system 63
6.12 Control panel with display 64
6.12.1 Removing and attaching the display 64
6.12.1.1 Removing the display 64
6.12.1.2 Attaching the display 64
6.12.2 Securing the display against removal 64
6.12.3 Charging the display battery 64
6.12.3.1 Charging on the pedelec 65
6.12.3.2 Charging using the USB port 65
6.12.4 Using the USB port 65
6.12.5 Switching on the display 65
6.12.6 Switching off the display 65
6.12.7 Using the push assist system 65
6.12.8 Using the riding light 65
6.12.9 Selecting the level of assistance 66
6.12.10 Journey information 66
6.12.10.1Switching the displayed journey
information 66
6.12.10.2Resetting the journey information 66
6.12.11 Changing the system settings 66
MY21B01 - 12_1.0_06.07.2020 4
Contents
6.13 Brake 67
6.13.1 Using the brake lever 68
6.14 Suspension and damping 69
6.15 Gear shift 70
7 Cleaning and servicing 71
7.1 Cleaning after each ride 71
7.1.1 Cleaning the suspension fork 71
7.1.2 Cleaning the pedals 71
7.2 Basic cleaning 72
7.2.1 Cleaning the frame 72
7.2.2 Cleaning the stem 72
7.2.3 Cleaning the wheel 72
7.2.4 Cleaning the drive elements 72
7.2.5 Cleaning the chain 73
7.2.6 Cleaning the battery 73
7.2.7 Cleaning the display 73
7.2.8 Cleaning the motor 73
7.2.9 Cleaning the brake 74
7.3 Servicing 74
7.3.1 Servicing the frame 74
7.3.2 Servicing the stem 74
7.3.3 Servicing the fork 74
7.3.4 Servicing the drive elements 74
7.3.5 Servicing the pedals 74
7.3.6 Servicing the chain 74
7.4 Maintenance 75
7.4.1 Wheel 75
7.4.1.1 Checking the tyres 75
7.4.1.2 Checking the rims 75
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 75
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve 76
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 76
7.4.2 Brake system 76
7.4.3 Checking the brake linings for wear 76
7.4.4 Checking the pressure point 77
7.4.5 Checking the brake discs for wear 77
7.4.6 Checking electrical cables and
brake cables 77
7.4.7 Checking the gear shift 77
7.4.8 Checking the stem 77
7.4.9 Checking the USB port 77
7.4.10 Checking the chain tension 77
8 Maintenance 78
8.1 Suspension system 79
8.1.1 Rear frame damper 79
8.1.2 Suspension fork 80
8.1.3 Suspension seat post 81
8.2 Axle with quick release 81
8.2.1 Checking the quick release 82
8.3 Maintaining the stem 82
8.4 Adjusting the gear shift 82
8.4.1 Cable-operated gear shift, single-cable 83
8.4.2 Cable-operated gear shift, dual-cable 83
8.4.3 Cable-operated twist grip, dual-cable 83
9 Troubleshooting, fault clearance and
repair 84
9.1 Troubleshooting and fault clearance 84
9.1.1 The drive system or display do not
start up 84
9.1.2 Error message 84
9.1.3 Assistance function errors 84
9.1.4 Battery error 85
9.1.5 Display errors 86
9.1.6 Lighting does not work 87
9.1.7 Other errors 87
9.2 Repair 88
9.2.1 Original parts and lubricants 88
9.2.2 Replacing the lighting 88
9.2.3 Adjusting the headlight 88
9.2.4 Tyre clearance check 88
10 Recycling and disposal 89
11 Documents 90
11.1 Parts list 90
11.1.1 Bulls Cross Mover Evo 1 90
11.1.2 Bulls Cross Mover Evo 2 91
11.2 Assembly report 92
11.3 Maintenance instructions 94
11.4 Charger operating instructions 97
12 Glossary 105
12.1 Abbreviations 107
12.2 Simplified terms 107
Appendix 108
I Translation of the original EC/EU
Declaration of Conformity 108
II Declaration of conformity for
incomplete machine 109
14 Keyword index 112
MY21B01 - 12_1.0_06.07.2020 5
About these operating instructions
Thank you for your trust!
BULLS pedelecs are premium quality bicycles.
You have made an excellent choice. Your
specialist dealer will provide you with guidance
and instruction and assemble your product. Your
specialist dealer will also be happy to assist you in
the future, whether you require maintenance,
conversion or repair.
You are receiving these operating instructions
with your new pedelec. Please take time to
become familiar with your new pedelec. Use the
tips and suggestions in the operating instructions.
They will help you to enjoy your pedelec for a long
time to come. We hope you have fun and wish you
well on all of your rides!
The operating instructions are mainly designed for
the rider or the operator. They aim to ensure that
non-professionals can use the pedelec safely.
Download the operating instructions onto your
phone at the following link, so that you can use
them when you are out riding:
www.bulls.de/service/
downloads.
Copyright
© ZEG Zweirad-Einkaufs-Genossenschaft eG
Distribution or reproduction of these operating
instructions and utilisation or communication of
their content is prohibited unless expressly
approved. Any infringement will render the
offender liable for compensation. All rights
reserved in the event that a patent, utility model or
industrial design is registered.
Editing
Text and images:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Translation:
RKT Übersetzungs- und Dokumentations-GmbH
Markenstrasse 7
40227 Düsseldorf, Germany
Notice
These operating instructions are not a substitute
for personal instruction by the supplying specialist
dealer.
These operating instructions are an integral part
of the pedelec. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Sections are also designed especially for the
specialist dealer. These sections aim to ensure
that specialist dealers complete initial assembly
and maintenance safely and reliably. The
sections for specialist dealers are highlighted in
grey and marked with a spanner symbol.
MY21B01 - 12_1.0_06.07.2020 6
About these operating instructions
1 About these operating
instructions
1.1 Manufacturer
The pedelec manufacturer is:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Tel.: +49 221 17959 0
Fax: +49 221 1795931
E-mail: info@zeg.de
Subject to internal changes
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes are included in a new
published version of the operating instructions.
You will find any modifications to these operating
instructions at:
www.bulls.de/service/downloads.
1.2 Language
The original operating instructions are written in
German. A translation is invalid without the
original operating instructions.
1.3 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
Machinery Directive 2006/42/EC
Electromagnetic Compatibility Directive
2014/30/EU
ISO 20607:2018 Safety of machinery
Instruction handbook General drafting
principles
EN 15194:2018 Cycles – Electrically power
assisted cycles – pedelec bicycles
EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
ISO 17100:2016-05 Translation Services
Requirements for translation services.
1.4 For your information
Different markings are used in the operating
instructions to make them easier to read.
1.4.1 Warnings
Warnings indicate hazardous situations and
actions. You will find warnings in the operating
instructions:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries if ignored.
Low-risk hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 7
About these operating instructions
1.4.2 Markups
You will find stylised forms of typeface in the
operating instructions:
Instructions for specialist dealers are highlighted
in grey. They are indicated by a screwdriver
symbol. Information for specialist dealers does
not require non-professionals to take any action.
Stylised form Use
Italics Glossary term
Underlined in blue Link
Underlined in grey Cross references
Check marks Requirements
Triangle Instruction for action
1Instruction for
action
Several instructions for
action in specified order
Result of the action
SPACED Indicators on the display
screen
Bulleted lists
Only applies to pedelecs
with this equipment Each type has a different
kind of equipment. A
note beneath the head-
ing indicates compo-
nents which can be used
as an alternative.
Table 1: Markups
MY21B01 - 12_1.0_06.07.2020 8
About these operating instructions
1.5 Nameplate
The nameplate is situated on the frame. You can
see the exact position of the nameplate in Figure 2.
You will find thirteen pieces of information on the
nameplate.
Figure 1: Example Nameplate
No. Designation Description
1CE marking The manufacturer uses the CE marking to declare that the pedelec complies with
applicable requirements.
2 Manufacturer's contact details You can contact the manufacturer at the address. You can find more information in
Section 1.
3 Type number All pedelec models have an eight-digit type number, which is used to specify the design
model year, the type of pedelec and the version. You can find more information in
Section 1.
4 Maximum continuous power The maximum continuous power is the greatest possible power for the electric motor
output shaft over 30 minutes.
5 Maximum permitted total weight The maximum permitted total weight is the weight of the fully assembled pedelec with the
rider and baggage.
6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2019 to July 2020.
7 Pedelec type You can find more information in Section 3.2.
8 Safety markings You can find more information in Section 1.4.
9 Disposal instructions You can find more information in Section 10.
10 Area of use You can find more information in Section 3.6.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version concerned. The year of manufacture is different to the model
year in some cases.
12 Weight of the ready-to-ride pedelec The weight of the ready-to-ride pedelec is specified as a weight of 25 kg or above and
refers to its weight at the time of purchase. You must add each additional accessory to
the weight.
13 Shut-off speed The speed that the pedelec reaches at the moment when the current has dropped to zero
or to the no-load current value.
Table 2: Nameplate details
ZEG Zweirad-Einkaufs-
Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
Typ:
21-17-1017
0,25 kW / 25 km/h
zGG 150 kg
EPAC 25 kg
BJ 2020 / MJ 2021
EN 15194
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
MY21B01 - 12_1.0_25.06.2020 9
About these operating instructions
1.6 Type number and model
These operating instructions are an integral part
of pedelecs with the type numbers:
1.7 Identifying the operating
instructions
The Identification number position is located on
bottom left-hand side on each page. The
identification number is composed of the
document number, the version number and the
release date.
Type no. Model Pedelec type
Table 3: Type number, model and pedelec type
Identification number MY21B01 - 12_1.0_09.07.2020
21-15-1016 BULLS Cross Mover
Evo 1, Trapez
21-15-1018 BULLS Cross Mover
Evo 1, Wave
21-15-1027 BULLS Cross Rider Evo 1
(München), Gent
21-15-1028 BULLS Cross Rider Evo 1
(München), Trapez
21-15-1069 BULLS Cross Street E1,
Gent
21-15-1070 BULLS Cross Street E1,
Trapez
21-17-1013 BULLS Cross Mover
Evo 2, Gent
21-17-1014 BULLS Cross Mover
Evo 2, Trapez
21-17-1015 BULLS Cross Mover
Evo 2, Wave
21-17-1029 BULLS Cross Rider Evo 2
(Cologne), Gent
21-17-1030 BULLS Cross Rider Evo 2
(Cologne), Trapez
21-17-1045 BULLS Cross Rider Evo 2
(Cologne), Wave
21-17-1064 BULLS Cross Mover
Evo 2, 26, Wave
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
MY21B01 - 12_1.0_25.06.2020 10
Safety
2 Safety
2.1 Residual risks
2.1.1 Risk of battery fire and explosion
The safety electronics may fail if the batteries are
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Only use and charge the battery and
accessories if they are in perfect condition.
Never open or repair the battery.
Batteries with external damage must be
removed from service immediately.
If a battery is dropped or struck, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods. Dispose
of faulty batteries in the correct manner. Store
battery in a dry place until disposal. Never
store in the vicinity of flammable substances.
The battery is only protected from spray water.
Penetration by water can cause a short circuit.
The battery may self-ignite and explode.
Never immerse the battery in water.
Put battery out of service if you suspect water
has penetrated it.
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. The battery may self-ignite and
explode.
Protect the battery against heat.
Never store next to hot objects.
Never expose the battery to sustained direct
sunlight.
Avoid wide temperature fluctuations.
2.1.2 Risk of fire and explosion due to
short circuit in the battery
Metal objects may connect the battery's electrical
terminals. The battery may self-ignite and
explode.
Never insert paper clips, screws, coins, keys
and other small parts into the battery.
Chargers with excessive voltage damage
batteries. This may result in fire or an explosion.
Only use batteries approved for the pedelec.
Clearly label the supplied charger.
2.1.3 Fire hazard caused by overheated
charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in fire
or burns to the hands.
Never use charger on a highly flammable
surface.
Never cover the charger during charging.
Never leave the battery unattended during
charging.
2.1.4 Electric shock caused by electric
drive system
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
2.1.5 Risk of a fall due to incorrectly set
quick releases
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
MY21B01 - 12_1.0_25.06.2020 11
Safety
2.1.6 Risk of fire and burns due to hot
motor
The motor housing becomes hot when riding.
Touching it may cause burns to the skin or other
objects.
Never touch the motor housing directly after
riding.
Never place the pedelec on a flammable
surface, such as grass or wood, directly after
use.
2.1.7 Key breaking off
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key to the battery lock.
2.2 Toxic substances
2.2.1 Brake fluid
Brake fluid may leak out after an accident or due
to material fatigue. Brake fluid can be fatal if
swallowed or inhaled.
Never dismantle the brake system.
Avoid contact with skin.
Do not inhale vapours.
2.2.2 Suspension oil
Suspension oil in the fork and the rear frame
damper is toxic to the touch, irritates respiratory
tracts and causes cancer, sterility and mutation in
germ cells.
Never dismantle the rear frame damper or the
suspension fork.
Avoid contact with skin.
2.2.3 Defective battery
Liquids and vapours may leak from damaged or
faulty batteries. Excessively high temperatures
may also cause liquids and vapours to leak from
the battery. Such liquids and vapours can irritate
the airways and cause burns.
Never dismantle the battery.
Avoid contact with skin.
Do not inhale vapours.
2.3 Requirements for the rider
The rider must demonstrate adequate physical,
motor and mental abilities to ride on public roads.
A minimum age of 14 years is recommended.
2.4 Vulnerable groups
Keep batteries and charger away from children
and people with reduced physical, sensory or
mental capabilities or lacking in experience and
knowledge.
If minors use the pedelec, a legal guardian must
should provide them with comprehensive
instructions.
2.5 Personal protective equipment
Wear a suitable cycling helmet, sturdy footwear
and typical close-fitting clothing to provide
protection.
2.6 Safety markings and safety
instructions
The nameplate contains these safety markings
and safety instructions:
Symbol Explanation
General warning
Adhere to the instructions for use
Table 4: Meaning of safety markings
MY21B01 - 12_1.0_25.06.2020 12
Safety
2.7 What to do in an emergency
2.7.1 Dangerous situation in road traffic
In the event of any hazards or dangers in road
traffic, apply the brakes on the pedelec until it
comes to a halt. The brake acts as an
emergency stop system in such cases.
2.7.2 Leaked brake fluid
Remove those affected from the danger area to
fresh air.
Never leave those affected unattended.
Immediately remove any clothing items
contaminated with brake fluid.
Never inhale vapours. Ensure sufficient
ventilation.
Wear gloves and safety gloves as protective
equipment.
Keep unprotected persons away.
Take care with leaked brake fluid as it poses a
slip hazard.
Keep leaked brake fluid away from naked
flames, hot surfaces and sources of ignition.
Avoid contact with skin and eyes.
After inhalation
Take in fresh air. Immediately consult a doctor
in case of any discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Rinse eyes under flowing water for at least ten
minutes with the lids open; also rinse under
lids. Immediately consult a doctor in case of
any pain or discomfort.
After swallowing
Rinse out mouth with water. Never induce
vomiting. Risk of aspiration!
If a person is lying on their back and vomiting,
place them in the recovery position. Seek
medical advice immediately.
Environmental protection measures
Never allow brake fluid to flow into the sewage
system, water courses or groundwater.
Notify the relevant authorities if fluid
penetrates the ground, water courses or the
sewage system.
Consult a doctor immediately in the event of
any pain or discomfort caused by combustion
gas or leaking fluids.
Symbol Explanation
Read the instructions
Separate collection of electrical
and electronic devices
Separate collection of ordinary
and rechargeable batteries
Must not be thrown into fire
(burning prohibited)
It is forbidden to open any
batteries
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct sunlight
Table 5: Safety instructions
max. 50°C
MY21B01 - 12_1.0_25.06.2020 13
Safety
2.7.3 Battery vapours emitted
Vapours may be emitted if the battery is damaged
or used improperly. The vapours may cause
respiratory tract irritation.
Get into fresh air.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Carefully rinse eyes with plenty of water for at
least 15 minutes. Protect unaffected eye. Seek
medical advice immediately.
After skin contact
Remove any solid particles immediately.
Rinse the affected area with plenty of water for
at least 15 minutes. Then dab the affected skin
gently. Do not rub dry.
Remove contaminated clothing immediately.
Immediately consult a doctor if there is any
redness, pain or discomfort.
2.7.4 Battery fire
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
1Keep your distance if the battery becomes
deformed or starts to emit smoke.
2If charging, remove the plug connector from
the socket.
3Contact the fire service immediately.
Use Class fire extinguishers to put out the fire.
Never extinguish damaged batteries with water
or allow them to come into contact with water.
Inhaling vapours can cause intoxication.
Stand on the side of the fire where the wind is
blowing from.
Use breathing apparatus if possible.
2.7.5 Leaked brake fluid
The brake system must be repaired immediately if
brake fluid leaks out. Dispose of leaking brake
fluid in an environmentally responsible way in
accordance with statutory regulations.
Contact your specialist dealer.
2.7.6 Oil and lubricant leaks from the fork
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in compliance with statutory
regulations.
Contact your specialist dealer.
2.7.7 Oil and lubricant leaks from the rear
frame damper
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in accordance with statutory
regulations.
Contact your specialist dealer.
MY21B01 - 12_1.0_25.06.2020 14
Overview
3Overview
Figure 2: Pedelec viewed from right, Bull Cross Rider used as example
1Front wheel
2Fork
3 Front guard
4 Headlight
5Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Reflector
11 Pannier rack
12 Rear guard
13 Rear light
14 Rear wheel
15 Chain
16 Frame number
17 Battery and nameplate
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 16 17
MY21B01 - 12_1.0_25.06.2020 15
Overview
3.1 Description
3.1.1 RANGE
Figure 3: Visible wheel components
1Tyres
2 Rim
3 Spoke
4 Spoke nipples
5 Hub,
6Valve
The wheel comprises the wheel itself, an inner
tube with a valve and a tyre.
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The pedelec has either
a classic Dunlop valve,
a French valve (also known as a Sclaverand or
Presta valve) or
a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series.
3.1.2.1 Rigid fork
Rigid forks do not feature suspension. They transfer
the used muscle and motor power to the road to
optimum effect. Pedelecs with rigid forks consume
less energy on steep roads and have a greater range
than pedelecs with adjusted suspension.
3.1.2.2 Suspension fork
A suspension fork is based either on a steel spring or
air suspension.
Unlike a rigid fork, a suspension fork has two
functions which improve floor contact and comfort:
suspension and damping. The suspension prevents
an impact, such as one caused by a stone lying in the
pedelec's path, from being channelled directly into
the rider's body via the fork. The impact is absorbed
by the suspension system instead. This causes the
suspension fork to compress.
Figure 4: Pedelec without suspension (1) and with
suspension (2)
After compressing, the suspension fork returns to
its original position. If there is a damper, it
decelerates movement, preventing the
suspension system from springing back in an
uncontrolled manner and stopping the fork from
vibrating up and down. Dampers which dampen
compressive deflection movements, i.e. a
compression load, are called compression
dampers or compression dashpots.
Dampers which dampen rebound deflection
movements, i.e. a rebound load, are called
rebound dampers or dashpots.
The compression can be disabled in any suspension
fork. A suspension fork will then behave like a rigid
fork.
1
2
3
6
5
4
12
MY21B01 - 12_1.0_25.06.2020 16
Overview
3.1.2.3 Steel suspension fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6).
Figure 5: Example showing Suntour fork
Other elements: the setting wheel for negative
deflection (9), crown (3), Q-Loc (5), dust seal (4),
fork end (7) and stanchion (8)
3.1.3 Brake system
Every pedelec has a hydraulic brake system. The
brake fluid is in a closed hose system. If the rider
pushes the brake lever, the brake fluid activates
the brake on the wheel.
The pedelec has either:
a rim brake on the front and rear wheels
a disc brake on the front and rear wheels or
a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the bicycle to a
halt quickly and safely in the event of an
emergency.
3.1.3.1 Disc brake
Figure 6: Brake system with disc brake – example
1Brake disc
2 Brake calliper with brake linings
3Handlebars with brake lever
4 Front wheel brake disc
5 Rear wheel brake disc
On a pedelec with a disc brake, the brake disc is
screwed permanently to the wheel hub. The brake
lever is pushed to increase brake pressure. The
brake fluid is used to transfer pressure through
the brake lines to the cylinders in the brake
calliper. The braking force is boosted by a speed
reduction and applied to the brake linings. These
apply the brake disc mechanically. If the brake
lever is pushed, the brake linings are pressed
against the brake disc and the wheel movement is
decelerated until it comes to a stop.
1
1
2
3
4
5
6
8
9
7
1
2
3
4
5
MY21B01 - 12_1.0_06.07.2020 17
Overview
3.1.4 Drive system
The pedelec is driven by muscle power applied to
the chain drive. The force which is applied by
pedalling in the direction of travel drives the front
chain wheel. The chain transmits the force onto
the rear chain wheel and then onto the rear wheel.
Figure 7: Diagram of mechanical drive system
1 Direction of travel
2 Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
The pedelec also has an integrated electric drive
system in addition to its mechanical drive system.
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the rider’s pedalling
motion. The pre-set level of assistance
determines the motor output.
The pedelec does not have a separate emergency
shut-off button. The electric drive system can be
stopped by removing the display in the event of an
emergency. The mechanical brakes are used as
an emergency stop system and bring the bicycle
to a halt quickly and safely in the event of an
emergency.
The motor switches off automatically as soon as
the rider no longer pedals, the temperature is
outside the permitted range, there is an overload
or the shut-off speed of 25 km/h has been
reached.
The electric drive system is made up of
8 components:
Figure 8: Diagram of electric drive system
1 Headlight
2 Display, more in Section 3.1.6
3 Control panel, more in Section 3.1.7
4.1 Integrated battery, more in Section 3.1.5.3
4.2 Frame battery, more in Section 3.1.5.1
4.3 Pannier rack battery, more in Section 3.1.5.2
5 Rear light
6 Electric gear shift (alternative)
7Motor
A charger designed for the battery.
A push assist system can be activated. The speed
depends on the selected gear. The push assist
continues to drive the pedelec as long as the rider
presses the push assist button on the handlebars.
The speed can be a maximum of 6 km/h in this
case. The electric drive stops when the push
assist button is released.
3.1.5 Rechargeable battery
Bosch batteries are lithium ion batteries which are
developed and manufactured to the latest
technical standards. Each individual cell is
protected by a steel cup and encased in a plastic
battery housing. These batteries meet and exceed
applicable industrial safety standards. The battery
has an internal electronic protection circuit, which
is specifically designed for the charger and the
pedelec. The battery temperature is monitored at
all times. The battery is protected against deep
discharge, overcharging, overheating and short
circuit. In the event of a hazard, a protective circuit
switches the battery off automatically.
5
2
4
1
B
3
1
2
4.2
4.1
4.3
5
6
7
MY21B01 - 12_1.0_06.07.2020 18
Overview
The battery has a high energy content when
charged. You will find codes of practice for their
safe handling in Section 2 Safety and Section 6.9
Rechargeable battery in the operating
instructions.
If the electric drive system is not used for about
10 minutes and no button has been pressed on
the display or the control panel, the electric drive
system and the battery are automatically switched
off to save energy.
The type and duration of operating conditions
have a significant effect on the battery life. Just
like any other lithium-ion battery, the battery will
age naturally if it is not being used. The battery's
service life can be extended if the battery is well
maintained and stored at the correct temperature.
The charging capacity will decrease with age,
even if the battery is maintained properly. If the
operating time is severely shortened after
charging, this is a sign that battery has reached
the end of its useful life.
Battery performance is reduced when the
temperature drops since this increases electrical
resistance. As a result, you can expect the range
to be shorter than normal in winter. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
The pedelec features either an integrated battery,
a pannier rack battery or a frame battery. Each
battery has its own lock.
3.1.5.1 Frame battery
Three different types of frame batteries can be
fitted:
Figure 9: Details of frame battery
1 Battery housing
2 Battery lock
3 Battery key
4 On-Off button (battery)
5 Battery level indicator (battery)
6 Charging port cover
7 Charging port
PowerPack 300 PowerPack 400 PowerPack 500
Table 6: Overview of frame batteries
1
2
3
4
5
678
MY21B01 - 12_1.0_06.07.2020 19
Overview
3.1.5.2 Pannier rack battery
Three different types of pannier rack batteries can
be fitted:
Figure 10: Overview of pannier rack battery
Figure 11: Details of pannier rack battery
1 Battery housing
2 Charging port
3 Charging port cover
4Battery lock
5Battery key
6 Battery level indicator (battery)
7 On-Off button (battery)
3.1.5.3 Integrated battery
Three different types of pannier rack batteries can
be fitted:
Figure 12: Overview of frame batteries
Figure 13: Integrated battery in detail
1 Battery key
2 Retainer guard
3 Securing hook
4 On-Off button (battery)
5 Battery level indicator (battery)
6 Battery housing
PowerPack 300 PowerPack 400 PowerPack 500
1
2
3
4
5
6
78
PowerTube 400 PowerTube 500 PowerTube 625
(vertical and horizontal)
1
2
3
4
5
2
6
MY21B01 - 12_1.0_06.07.2020 20
Overview
3.1.6 Display
The model series to which these instructions
apply features the BOSCH Intuvia display. In addi-
tion to the functions described here, software
changes may be introduced to rectify errors and
extend functions at any time. The display controls
the electric drive system with four operating ele-
ments and shows the journey data. The rider can
switch off the electric drive system by removing
the display. The battery powers the display if the
display is inserted in the mount, a sufficiently
charged battery is inserted into the pedelec and
the electric drive system is switched on.
If the rider removes the display from its mount, the
display is powered by a display battery. The
display battery cannot be replaced.
Figure 14: BOSCH Intuvia display
3.1.7 Control panel
The control panel controls the electric drive
system.
Figure 15: Control panel overview
3.1.7.1 USB port
There is a USB port beneath the rubber cover on
the right-hand edge of the display.
3.1.8 Riding light
When the riding light is activated, the headlight
and the rear light are switched on together.
3.1.9 Charger
Each pedelec is supplied with a charger. As a
general rule, any BOSCH charger may be used:
The 2 A compact charger
The 4 A standard charger
The 6 A fast charger
Observe the operating instructions in the
Section 11 on Documents.
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
P MWH
MIN
MPH
KM
/H
MY21B01 - 12_1.0_25.06.2020 21
Overview
3.2 Proper use
The pedelec must only be used in perfect, fully
functional condition. National requirements may
apply to the pedelec which the standard
equipment may not meet. For riding on public
roads, some special regulations apply in relation
to the riding light, reflectors and other components.
The general laws and the regulations for the
prevention of accidents and environmental
protection in the respective country of use must be
adhered to. All check lists and instructions for
actions in these operating instructions met.
Approved accessories can be installed by
specialist staff.
The rechargeable batteries are designed to
supply power to the pedelec motor only and must
not be used for other purposes.
Each pedelec is assigned a Pedelec type, which
determines its proper usage, function and area of
use.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are designed
for daily, comfortable
use. They are
suitable for riding on
public roads.
The legal guardians
of minor riders must
read and understand
these operating
instructions before
commissioning.
The contents of these
operating
instructions must be
communicated to the
riders in an age-
appropriate manner.
The cycles for
children and young
adults are suitable for
riding on public
roads. The size of the
pedelec must be
checked regularly for
orthopaedic reasons.
A check must be
made at least every
three months to make
sure that the
maximum permitted
total weight is being
observed.
Mountain bikes are
designed for sporting
use. The design
characteristics
include a short
wheelbase, a sitting
position with the rider
inclined towards the
front, and a brake
requiring low
actuation force.
A mountain bike is a
piece of sporting
equipment. It requires
an adaptation period
and the rider must be
physically fit. Use
requires the
appropriate training;
in particular riding in
bends and braking
should be practised.
The strain on the
rider, in particular the
hands and wrists,
arms, shoulders,
neck and back, is
accordingly high.
Inexperienced riders
tend to brake
excessively and lose
control as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road
surface.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is
characterised by its
lightweight structure
and a design which is
stripped to the
minimum parts
required for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicycle
can be ridden at high
speeds. The frame
design requires
practice to ensure the
ride is able to ride
slowly, apply the
brakes and get on
and off the bike
safely.
The sitting position is
athletic. The strain on
the rider, in particular
the hands and wrists,
arms, shoulders,
neck and back, is
accordingly high. The
sitting position
therefore requires
physical fitness.
The cargo bike is
suitable for daily
transportation of
loads on public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied
loading conditions
and weight
distributions require
special practice and
skill when braking
and riding in bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
You need to be
cautious when riding
a cargo bike. You
must pay attention to
the traffic on public
roads and the
condition of the route
accordingly.
The folding bicycle is
suitable for use on
public roads.
A folding bicycle can
be folded up and is
thus suitable for
space-saving
transportation, for
example on public
transport or in a car.
The folding function
of the folding bicycle
makes it necessary to
use smaller wheels
and longer brake
cables and Bowden
cables. Therefore, in
case of an increased
load, a reduction in
riding stability and
braking power,
diminished comfort
and reduced
durability are to be
expected.
Table 7: Proper use for each pedelec type
MY21B01 - 12_1.0_25.06.2020 22
Overview
3.2.1 Maximum permitted total weight
The pedelec may only be loaded to its maximum
permitted total weight (PTW). The maximum
permitted total weight is the weight of the fully
assembled pedelec with the rider and baggage.
3.2.2 Data privacy information
When the pedelec is connected to the BOSCH
diagnosis tool, data is transferred to Bosch eBike
Systems (Robert Bosch GmbH) regarding the use
of rechargeable battery, including its temperature
and cell voltage, to help improve the product. You
will find more detailed information on the BOSCH
website: www.bosch-ebike.com/en/.
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the pedelec in the following
ways:
when the electrical drive system has been
manipulated
riding with a damaged or incomplete pedelec
riding over steps
riding through deep water
charging with an incorrect charger
lending the pedelec to untrained riders
carrying other people
riding with excessive baggage
riding with no hands
riding on ice and snow
improper servicing
improper repair
tough areas of use, such as professional
competitions
stunt riding or acrobatics.
Type no. Model PTW
21-17-1013 Bulls Cross Mover Evo 2 150 kg
21-17-1014 Bulls Cross Mover Evo 2 150 kg
21-17-1015 Bulls Cross Mover Evo 2 150 kg
21-17-1016 Bulls Cross Mover Evo 1 150 kg
21-17-1017 Bulls Cross Mover Evo 1 () 150 kg
21-17-1018 Bulls Cross Mover Evo 1 150 kg
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 8: Information on improper use
MY21B01 - 12_1.0_25.06.2020 23
Overview
3.4 Proper use
The pedelec must only be used in perfect, fully
functional condition. National requirements may
apply to the pedelec which the standard
equipment may not meet. For riding on public
roads, some special regulations apply in relation
to the riding light, reflectors and other components.
The general laws and the regulations for the
prevention of accidents and environmental
protection in the respective country of use must be
adhered to. All check lists and instructions for
actions in these operating instructions met.
Approved accessories can be installed by
specialist staff.
The rechargeable batteries are designed to
supply power to the pedelec motor only and must
not be used for other purposes.
Each pedelec is assigned a Pedelec type, which
determines its proper usage, function and area of
use.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are designed
for daily, comfortable
use. They are
suitable for riding on
public roads.
The legal guardians
of minor riders must
read and understand
these operating
instructions before
commissioning.
The contents of these
operating
instructions must be
communicated to the
riders in an age-
appropriate manner.
The cycles for
children and young
adults are suitable for
riding on public
roads. The size of the
pedelec must be
checked regularly for
orthopaedic reasons.
A check must be
made at least every
three months to make
sure that the
maximum permitted
total weight is being
observed.
Mountain bikes are
designed for sporting
use. The design
characteristics
include a short
wheelbase, a sitting
position with the rider
inclined towards the
front, and a brake
requiring low
actuation force.
A mountain bike is a
piece of sporting
equipment. It requires
an adaptation period
and the rider must be
physically fit. Use
requires the
appropriate training;
in particular riding in
bends and braking
should be practised.
The strain on the
rider, in particular the
hands and wrists,
arms, shoulders,
neck and back, is
accordingly high.
Inexperienced riders
tend to brake
excessively and lose
control as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road
surface.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is
characterised by its
lightweight structure
and a design which is
stripped to the
minimum parts
required for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicycle
can be ridden at high
speeds. The frame
design requires
practice to ensure the
ride is able to ride
slowly, apply the
brakes and get on
and off the bike
safely.
The sitting position is
athletic. The strain on
the rider, in particular
the hands and wrists,
arms, shoulders,
neck and back, is
accordingly high. The
sitting position
therefore requires
physical fitness.
The cargo bike is
suitable for daily
transportation of
loads on public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied
loading conditions
and weight
distributions require
special practice and
skill when braking
and riding in bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
You need to be
cautious when riding
a cargo bike. You
must pay attention to
the traffic on public
roads and the
condition of the route
accordingly.
The folding bicycle is
suitable for use on
public roads.
A folding bicycle can
be folded up and is
thus suitable for
space-saving
transportation, for
example on public
transport or in a car.
The folding function
of the folding bicycle
makes it necessary to
use smaller wheels
and longer brake
cables and Bowden
cables. Therefore, in
case of an increased
load, a reduction in
riding stability and
braking power,
diminished comfort
and reduced
durability are to be
expected.
Table 9: Proper use for each pedelec type
MY21B01 - 12_1.0_25.06.2020 24
Overview
3.5 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the pedelec in the following
ways:
when the electrical drive system has been
manipulated
riding with a damaged or incomplete pedelec
riding over steps
riding through deep water
charging with an incorrect charger
lending the pedelec to untrained riders
carrying other people
riding with excessive baggage
riding with no hands
riding on ice and snow
improper servicing
improper repair
tough areas of use, such as professional
competitions
stunt riding or acrobatics.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 10: Information on improper use
MY21B01 - 12_1.0_25.06.2020 25
Overview
3.5.1 Maximum permitted total weight
The pedelec may only be loaded to its maximum
permitted total weight (PTW). The maximum
permitted total weight is the weight of the fully
assembled pedelec with the rider and baggage.
3.5.2 Data privacy information
When the pedelec is connected to the BOSCH
diagnosis tool, data is transferred to Bosch eBike
Systems (Robert Bosch GmbH) regarding the use
of rechargeable battery, including its temperature
and cell voltage, to help improve the product. You
will find more detailed information on the BOSCH
website: www.bosch-ebike.com/en/.
Type no. Model PTW
21-17-1013 Bulls Cross Mover Evo 2 150 kg
21-17-1014 Bulls Cross Mover Evo 2 150 kg
21-17-1015 Bulls Cross Mover Evo 2 150 kg
21-17-1016 Bulls Cross Mover Evo 1 150 kg
21-17-1017 Bulls Cross Mover Evo 1 () 150 kg
21-17-1018 Bulls Cross Mover Evo 1 150 kg
MY21B01 - 12_1.0_25.06.2020 26
Overview
3.6 Environmental requirements
You can be ride the pedelec within a temperature
range between 5 °C and 35 °C. The electric drive
system is limited in its performance outside this
temperature range.
During winter use, especially at temperatures
below 0 °C, we recommend that you don't insert a
battery charged and stored at room temperature
into the pedelec until just before setting off. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
Temperatures under -10 °C and over +50 °C must
be avoided.
You must also keep within the following
temperature ranges:
The nameplate contains symbols for the pedelec's
area of use. Check what roads and paths you may
use before you ride the bicycle for the first time.
Optimal operating temperature 22 °C - 26 °C
Transportation temperature 10 °C - 40 °C
Storage temperature 10 °C - 40 °C
Work environment temperature 15 °C - 25 °C
Charging temperature 10 °C - 40 °C
Table 11: Pedelec technical data
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes
and jumps up to
15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes
and jumps up to
15 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
sections with
moderate slopes
and jumps up to
61 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
limited downhill use
and jumps up to
122 cm.
Table 12: Area of use
MY21B01 - 12_1.0_25.06.2020 27
Overview
The pedelec is unsuitable for the following areas of use:
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never ride downhill
or perform jumps
over 61 cm.
Never traverse
extremely difficult
off-road terrain or
perform jumps over
122 cm.
MY21B01 - 12_1.0_06.07.2020 28
Overview
3.7 Technical data
3.7.1 Pedelec
3.7.2 Emissions
*The safety requirements as per Electromagnetic Compatibility
Directive 2014/30/EU have been met. The pedelec and the
charger can be used in residential areas without restriction.
3.7.3 Tightening torque
*if there is no other data on the component
3.7.4 Intuvia display
3.7.5 USB port
3.7.6 Active Line motor
3.7.7 Active Line Plus motor
Transportation temperature C - 2C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 10 °C - 30 °C
Ideal storage temperature 10 °C - 15 °C
Operating temperature C - 3C
Work environment temperature 15 °C - 25 °C
Charging temperature C - 4C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 13: Pedelec technical data
A-weighted emission sound pressure
level
<70dB(A)
Total vibration level for the hands and
arms
<2.5m/s²
Highest effective value of weighted
acceleration for the entire body
<0.5m/s²
Table 14: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 15: Tightening torque values
Internal lithium ion battery 3.7 V, 230 mAh
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +50 °C
Charging temperature C - + 4C
Protection rating
(with USB cover closed)
IP54
Weight about 0.15 kg
Table 16: Intuvia display technical data (BUI255)
Charge voltage 5V
Charging current Max. 500 mA
Table 17: USB port technical data
Maximum continuous power 250 W
Max. torque 40 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 2.9 kg
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +40 °C
Table 18: Technical data for Active Line BDU310 motor
Maximum continuous power 250 W
Max. torque 50 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 3.2 kg
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +40 °C
Table 19: Technical data for Active Line Plus BDU350 motor
MY21B01 - 12_1.0_06.07.2020 29
Overview
3.7.8 Performance Line motor
3.7.9 Performance Line Cruise motor
3.7.10 Bicycle lighting
3.7.11 PowerPack 300 battery
3.7.12 PowerPack 400 battery
3.7.13 PowerPack 500 battery
Maximum continuous power 250 W
Max. torque 65 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 3.2 kg
Operating temperature -5 - +40 °C
Storage temperature -10 - +40 °C
Table 20: Technical data for Performance Line BDU365 motor
Maximum continuous power 250 W
Max. torque 63 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 4 kg
Operating temperature -5 °C - +40 °C
Storage temperature -1C - +5C
Table 21: Technical data for Performance Line Cruise
BDU250P motor technical
Voltage about 12 V
Maximum output
Front light 17.4 W
Rear light 0.6 W
Table 22: Bicycle lighting technical data
Nominal voltage 36 V
Nominal capacity 8.2 Ah
Energy 300 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 23: Technical data for PowerPack 300, BBS245 and
BBR245 batteries
Nominal voltage 36 V
Nominal capacity 11 Ah
Energy 400 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 24: Technical data for PowerPack 400, BBS265 and
BBR265 batteries
Nominal voltage 36 V
Nominal capacity 13.4 Ah
Energy 500 Wh
Weight 2.6/ 2.7 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 25: Technical data for PowerPack 500, BBS275 and
BBR275 batteries
MY21B01 - 12_1.0_06.07.2020 30
Overview
3.7.14 PowerTube 400 battery
3.7.15 PowerTube 500 battery
3.7.16 PowerTube 625 battery
3.7.17 BOSCH pedelec ABS BAS100
Nominal voltage 36 V
Nominal capacity 11 Ah
Energy 400 Wh
Weight 2.9 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 26: Technical data for PowerTube 400, BBP282 and
BBP283 vertical batteries
Nominal voltage 36 V
Nominal capacity 13.4 Ah
Energy 500 Wh
Weight 2.9 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 27: Technical data for PowerTube 500, BBP280
horizontal and BBP281 vertical batteries
Nominal voltage 36 V
Nominal capacity 16.7 Ah
Energy 625 Wh
Weight 3.5 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 28: Technical data for PowerTube 625, BBP282
horizontal and BBP283 vertical batteries
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +60 °C
Protection class IPx7
Weight about 1kg
Table 29: BOSCH pedelec ABS BAS100 technical data
MY21B01 - 12_1.0_09.07.2020 31
Overview
3.8 Description of controls and
screens
3.8.1 Handlebars
Figure 16: Detailed view of handlebars from rider position,
example
1 Rear brake lever
2Bell
3 Headlight
4 Display
5 Front brake lever
6 Control panel
8 Fork lock on the suspension fork
9Shifter
3.8.2 Rechargeable battery
Figure 17: Battery level indicator; frame battery used as
example
1 On-Off button (battery)
2 Battery level indicator (battery)
The five green LEDs on the battery level indicator
indicate the charge level when the rechargeable
battery is switched on. Each LED represents
about 20% of battery capacity. All five LEDs will
light up when the battery is fully charged. If the
battery level falls below 5%, all the LEDs will go
out. The charge level is also displayed by the
battery level indicator (battery).
3.8.3 Display
The display has four buttons and a USB port.
Figure 18: Overview of the structure of the display's
operating elements
1 Display housing
2 Riding light button
3 Info button (display)
4 RESET button
5 On-Off button (display)
6 Display mount
7USB port
8 USB port protective flap
3.8.4 Control panel
The control panel has four buttons.
Figure 19: Control panel overview
1 Info button (control panel)
2 Control panel housing
3 Push assist button
4 Plus button
5 Minus button
1
2
5
6
4
7
8
3
1
2
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURB O
SPOR T
S
TOUR
ECO
OFF
MPH
KM/ H
Reichweite
AMM
PMW H
MIN
MPH
KM
/H
1
2
3
4
5
6
78
1
2
3
4
5
MY21B01 - 12_1.0_09.07.2020 32
Overview
3.8.5 On-screen indicators
The display has seven on-screen indicators:
Figure 20: On-screen indicators overview
1 Riding light indicator, see Section 3.8.5.1.
2 Level of assistance indicator, see Section
3.8.5.2.
3 Motor power used indicator, see Section
3.8.5.4.
4 Battery level indicator (display screen), see
Section 3.8.5.3.
5 Gear recommendation indicator, see Section
3.8.5.5.
6 Tachometer indicator, see Section 3.8.5.6.
7 Function display, see Section 3.8.5.7.
3.8.5.1 Riding light indicator
The riding light indicator lights up when the riding
light is activated.
3.8.5.2 Level of assistance indicator
The higher the selected level of assistance, the
more the electric drive system assists the rider
when pedalling. These levels of assistance are
available.
3.8.5.3 Battery level indicator (display
screen)
The battery level indicator displays the pedelec
battery level, not the level for the display internal
battery. If the display is removed from its mount,
the last level message is saved. Each bar in the
battery symbol on the screen represents about
20% capacity.
If a pedelec is used with two batteries, the battery
level indicator shows the charge level for both
batteries.
If both batteries are being charged on a pedelec,
the function display shows the charging progress
for both batteries. You can see which of the two
batteries is currently being charged by the
flashing indicator on the battery.
Figure 21: The left-hand battery is being charged
You can also see the battery charge level on the
level indicator LEDs (battery).
Level of assistance Use
SPORT Powerful assistance, for sport rides on
mountainous rides and on urban roads.
eMTB (instead of SPORT) effective assistance
with optimum efficiency for maximum
range.
TURBO Maximum assistance up to high
pedalling frequencies for sport riding.
TOUR Constant assistance, for long-range
tours
ECO Effective assistance with maximum
efficiency for maximum range.
Table 30: Overview of levels of assistance, standard
5
1
2
3
4
6
7
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM/H
5
Symbol Meaning
The battery is fully charged.
The battery needs to be recharged.
The LEDs on the battery level indicator have
gone out. The capacity for drive assistance has
been used up and assistance is gently switched
off. The remaining capacity is reserved for
lighting and the display. The screen flashes.
The battery capacity is sufficient for about
2 hours more lighting. Other electrical loads,
such as automatic gears and charging of
external devices connected to the USB port,
are not taken into account here.
Table 31: Overview of battery level indicator
OF
MP
H
KM
/
MY21B01 - 12_1.0_09.07.2020 33
Overview
3.8.5.4 Indicator for motor power used
If the motor is active, the indicator for the motor
power used is shown on the display screen. The
maximum motor power depends on the selected
level of assistance. A long bar indicates high
power consumption.
3.8.5.5 Gear recommendation indicator
Pedalling frequencies higher than 50 revolutions
per minute optimise drive unit efficiency.
However, very slow pedalling uses up a great deal
of energy. The speed and range can be increased
while applying the same force if you select the
right gear.
The gear recommendation function reacts to
excessively slow or excessively quick pedalling
and recommends a change of gear.
The gear recommendation function has to be
switched on in the system settings.
3.8.5.6 Tachometer indicator
The tachometer indicator shows the current
speed at all times.
You can select whether the speed is displayed in
kilometres or miles in the system settings.
3.8.5.7 Function display
The function display shows texts and readings.
Three different types of information are shown:
Journey information,
System settings and data, and
System messages.
3.8.5.8 Journey information
Depending on the type of pedelec, the function
display may show up to seven journey information
items. The displayed journey information can be
switched.
3.8.5.9 Additional journey information
Only applies to Shimano DI2 automatic hub gears
The following additional functions are available on
the function display:
Applies only to eShift with manual Shimano DI2 hub gears
The following additional functions are available on
the function display:
Applies only to eShift with Shimano DI2 automatic hub gears
The following additional functions are available on
the function display:
Symbol Use
Pedalling frequency is too high, a higher gear is
recommended
Pedalling frequency is too low, a lower gear is
recommended
Table 32: Symbols of the gear recommendation function
indicator Function
CLOCK Current time
MAX. SPEED Maximum speed reached since the
last RESET
AVG. SPEED Average speed reached since the last
RESET
TRIP TIME Journey time since last RESET
RANGE Estimated range of the available
battery charge
ODOMETER Display of the total distance travelled
(cannot be changed)
TRIP DISTANCE Distance travelled since the last
RESET
Table 33: Journey information
indicator Change
AUTO: ON/AUTO: OFF
This menu option indicates
whether the automatic mode is
switched on or off.
Table 34: Additional journey information
indicator Change
GEAR
The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 35: Additional journey information
indicator Change
GEAR
The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 36: Additional journey information
MY21B01 - 12_1.0_09.07.2020 34
Overview
Applies only to eShift with NuVinci H|Sync/enviolo with
Optimized H|Sync
The following additional functions are available on
the function display:
Applies only to eShift with Rohloff E-14 Speedhub 500/14
The following additional functions are available on
the function display:
3.8.5.10 System settings and data
In order to see the system settings and data, the
rider has to call up the system settings. The rider
can change the values of the system settings, but
not the system data.
3.8.5.11 Additional system settings
Applies only to eShift with Shimano DI2 automatic hub gears
Applies only to eShift with manual Shimano DI2 hub gears.
indicator Change
± NUVINCI CADENCE /
± NUVINCI GEAR
The current gear shift is shown
on the display screen. The new
gear is shown briefly on the
screen each time it is changed.
The standard setting is
± NuVinci cadence.
Table 37: Changing the system settings
INDICATOR Change
GEAR
The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 38: Changing the system settings
indicator Function
- CLOCK + Changes the time
- WHEEL CIRC UM + Wheel circumference in mm
- ENGLISH + Changes the language
- UNIT KM/MI + Selects whether the speed and
distance are displayed in
kilometres or miles
- TIME FORMAT + Select whether the time is
displayed in 12-hour clock or
24-hour clock format
- SHIFT RECOM.OFF + Switches the gear
recommendation on and off
Table 39: Changeable system settings
indicator Function
POWER ON HOURS Display of the total journey duration
DISPL. VX.X.X.X Display software version
DU VX.X.X.X Drive system software version
DU# XXXX XXXXX Drive system serial number
SERVICEMM/YYYY (Alternative) defined inspection
date
SERV. XX KM/MI (Alternative) defined inspection
BAT. VX.X.X.X Software version
1.BAT VX.X.X.X Software version
2.BAT VX.X.X.X Software version
Table 40: System information, unvarying
indicator Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position
– –. This menu option is only
shown when the display is
positioned in its mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer's operating
instructions. Make the fine
adjustment as soon as you hear
any unusual noises from the gear
shift. This menu option is only
shown when the display is
positioned in its mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 41: Changing the system settings
indicator Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position –
–. This menu option is only shown
when the display is positioned in its
mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer's operating
instructions. Make the fine
adjustment as soon as you hear any
unusual noises from the gear shift.
This menu option is only shown
when the display is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the display is positioned in its
mount. This menu option is only
shown if you have an electronic
control gear.
Table 42: Changing the system settings
MY21B01 - 12_1.0_09.07.2020 35
Overview
Applies only to eShift with Shimano DI2 automatic hub gears.
Applies only to eShift with NuVinci H|Sync/enviolo with
Optimized H|Sync
Applies only to eShift with Rohloff E-14 Speedhub 500/14.
3.8.6 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 information and a table for all system
messages in Section 6.2.
3.8.7 ABS indicator lamp
The anti-blocking system indicator lamp must light
up after the system has started up and must go
out once speed has reached about 5 km/h. If the
ABS indicator lamp remains unlit when the electric
drive system starts, the ABS is defective. An error
code on the display screen also tells the rider that
it is defective. If the indicator lamp does not go out
after you set off or it lights up while you are riding,
this means there is an error in the anti-blocking
system. The anti-blocking system is inactive in
such a case. The brake system itself remains
functional. It is only the anti-blocking system
control which no longer operates.
If the ABS indicator lamp is lit, the ABS function is
disabled.
indicator Change
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer's operating
instructions. Make the fine
adjustment as soon as you hear any
unusual noises from the gear shift.
This menu option is only shown
when the display is positioned in its
mount.
Gear recovery You can use this menu option to
reset the rear derailleur if it has been
detached – due to a crash or impact
against the derailleur, for example.
You will find a description of how to
reset the gear shift in the gear shift
manufacturer's operating
instructions. This menu option is
only shown when the display is
positioned in its mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the display is positioned in its
mount. This menu option is only
shown if you have an electronic
control gear.
Table 43: Changing the system settings
indicator Change
Gear calibration This is where you can perform a
calibration on the stepless gear.
Press on the Lighting button to
confirm calibration. Then follow the
instructions. You might need to
perform calibration while riding in
the event of a fault. In such cases,
you press on the "Lighting" button
to confirm you require calibration
and then follow the instructions on
the display screen. This menu
option is only shown when the
display is positioned in its mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the display is positioned in its
mount. This menu option is only
shown if you have an electronic
control gear.
Table 44: Changing the system settings
indicator Change
Start gear This is where you can set the start
gear. The automatic gear switch
function is switched off in
Position – –.
This menu option is only shown if
the display is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the display is positioned in its
mount. This menu option is only
shown if you have an electronic
control gear.
Table 45: Changing the system settings
Notice
The anti-blocking system indicator lamp may light
up if the front and rear wheels are rotating at
widely different speeds from one another – for
example, if the rider cycles on the rear wheel only
or if a wheel is rotating for a unusually long time
without making contact with the ground (fitting
stand). The anti-blocking system switches off in
such cases.
1Stop pedelec to reactivate the anti-blocking
system.
2Restart pedelec (turn off and on again).
MY21B01 - 12_1.0_25.06.2020 36
Transporting and storing
4 Transporting and storing
4.1 Physical transport
characteristics
4.1.1 Weight and dimensions during
transportation
*This information was not yet available at the time
of going to press. You'll find the information in the
latest operating instructions on the service portal.
4.1.2 Designated handles/lifting points
The box does not have any handles.
4.2 Transporting
When shipping the pedelec, we recommend that
you have the specialist dealer partially dismantle
the pedelec and place it in the proper packaging.
Take into account the weight of the ready-to-
use pedelec when transporting it.
Protect the electrical components and
connections on the pedelec from the weather
conditions with suitable protective covers.
Transport the battery in a dry, clean position
where it is protected from direct sunlight.
4.3 Storing
Store pedelec, battery and charger in a clean,
dry place where they are protected from
sunlight. Do not store outdoors to ensure a
long service life.
Temperatures under -10 °C or over +60 °C must
generally be avoided.
Storage at about 10 °C to 20 °C is beneficial to a
long battery life.
Store pedelec, battery and charger separately.
Type no. Frame Weight Size
21-17-1016
45 * *
50 * *
55 * *
60 * *
21-17-1017
45 * *
50 * *
55 * *
21-17-1018
50 * *
55 * *
60 * *
21-17-1013
45 * *
50 * *
55 * *
60 * *
21-17-1014
45 * *
50 * *
55 * *
21-17-1015
45 * *
50 * *
55 * *
Crash caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery.
Optimum pedelec storage temperature 10 °C - 20 °C
Table 46: Storage temperature for batteries and the pedelec
CAUTION
!
MY21B01 - 12_1.0_25.06.2020 37
Transporting and storing
4.3.1 Break in operation
If the pedelec is removed from service for longer
than four weeks, you need to prepare it for a break
in operation.
4.3.1.1 Preparing a break in operation
Remove battery from the pedelec.
Charge battery to around 30% - 60%.
The pedelec needs to be cleaned with a damp
cloth and preserved with wax spray. Never wax
the friction surfaces of the brake.
Before longer periods without use, it is
recommendable to have your specialist dealer
carry out an inspection and basic cleaning and
apply preservative agent.
4.3.1.2 Taking out of operation
1Store the pedelec, battery and charger in a dry,
clean environment. We recommend storing
them in uninhabited rooms with smoke alarms.
Dry locations with an ambient temperature of
about 10 °C to 20 °C are ideal.
2Recharge the display battery for at least 1 hour
every 3 months.
3Check the battery level after 6 months. If only
one LED on the battery level indicator lights up,
recharge the battery to around 30% - 60%.
Notice
The battery discharges when not in use. This can
cause irreparable damage to the battery.
The battery must be recharged every
6 months.
The battery may become damaged if it is
connected permanently to the charger.
Never connect the battery to the charger
permanently.
The display battery discharges when it is not in
use. This can cause it to be irreparably damaged.
Recharge the display battery for at least
1 hour every 3 months.
MY21B01 - 12_1.0_06.07.2020 38
Assembly
5 Assembly
Assemble the pedelec in a clean, dry
environment.
The work environment temperature should be
between 15 °C and 25 °C.
The fitting stand used must be approved for a
maximum weight of at least 30 kg.
5.1 Required tools
The following tools are required to assemble the
pedelec:
5.2 Unpacking
The packaging material consists mainly of
cardboard and plastic film.
The packaging has to be disposed of in accord-
ance with the regulations of the authorities.
5.2.1 Scope of delivery
Pedelecs are fully assembled in the factory for
test purposes and then dismantled for
transportation.
The pedelec is 95 - 98% pre-assembled. The
scope of delivery includes:
the pre-assembled pedelec
the front wheel
the pedals
quick release (optional)
the charger
the operating instructions.
The battery is supplied separately from the
pedelec.
5.3 Preparing the battery
5.3.1 Checking the battery
The battery must be checked before it is charged
for the first time.
1Press the On-Off button (battery).
If none of the LEDs on the battery level
indicator light up, the battery may be damaged.
The battery may be fully charged if at least one,
but not all, of the LEDs on the battery level
indicator is lit up.
5.3.2 Retrofitting a PowerTube
Adapter 400 or 500
A PowerTube Adapter 400 or 500 needs to be
retrofitted to use a Bosch PowerTube 625 battery.
1Use a TORX® T25 wrench to undo the screws
in the battery mount.
Figure 22: Undoing screws on battery mount
Risk of eye injury
Problems may arise if the settings are not made
to components correctly and you may sustain
serious injuries as a result.
Always wear safety glasses to protect your
eyes during assembly.
Crash and crushing hazard caused by
unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery.
•Knife
Hexagon socket spanner 2 (2.5 mm, 3 mm,
4 mm, 5 mm, 6 mm and 8 mm)
Torque wrench with working range between
5and 40Nm
•Ratchet,
Twelve-point square socket T25
Ring spanner (8 mm, 9 mm, 10 mm), 13 mm,
14 mm and 15 mm) and
Cross, flat head and ordinary screwdriver.
TORX® T25 wrench l
WARNING
!
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 39
Assembly
2Use a ratchet to remove the two 4 mm hexagon
screws in the PowerTube adapter. If you don't
have a ratchet, you can use a hexagonal key to
remove the screws.
Figure 23: Removing the 4 mm hexagon screws
3Use a ratchet to remove the two 4 mm hexagon
screws in the PowerTube adapter.
Figure 24: Removing hexagon screws
4Pull out the PowerTube adapter.
Figure 25: Pulling out the PowerTube adapter
5Use adapter plates to adjust the distance if
necessary.
Figure 26: Fitted adapter plates
6Use a TORX® T25 wrench to fasten the screws
into the battery mount.
Figure 27: Fastening the battery mount
MY21B01 - 12_1.0_06.07.2020 40
Assembly
5.4 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.
For this reason, every pedelec must be
prepared, so it is fully ready for use
immediately after being assembled.
The assembly report (see Section 11.2)
describes all safety-relevant inspections, tests
and maintenance tasks for the bicycle in a
separate list. All assembly work must be
completed to ensure the pedelec is ready to
ride.
Complete an assembly report for quality
assurance purposes.
5.4.1 Installing the wheel in the Suntour
fork
5.4.1.1 Screw-on axle (15 mm)
Only applies to Suntour forks with 15 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 28: Fully inserting the axle
2Tighten the axle to 8–10 Nm with a 5 mm
hexagon socket spanner.
Figure 29: Tightening the axle
3Insert the securing screw on the non-drive
side.
Figure 30: Pushing the quick release lever into the axle
Burns from hot drive
The drive cooler can become extremely hot
during use. Touching it may cause burns.
Leave the drive unit to cool before assembly.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 41
Assembly
4Tighten the securing screw with a 5 mm
hexagon socket spanner to 5-6 Nm.
The lever is mounted.
Figure 31: Tightening the securing screw
5.4.1.2 Screw-on axle (20 mm)
Only applies to Suntour forks with 20 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 32: Tightening the inserted axle
2Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 33: Tightening the securing clip
5.4.1.3 Quick release axle
Only applies to Suntour forks with screw-on axle
1Insert the axle into the hub on the drive side.
Figure 34: Pushing the axle into the hub
Crash caused by loose quick release axle
A faulty or incorrectly installed quick release axle
may become caught in the brake disc and block
the wheel. This will cause a crash.
Never fit a defective quick release axle.
Crash caused by faulty or incorrectly
installed quick release axle
The brake disc becomes very hot during
operation. Parts of the quick release axle may
become damaged as a result. The quick release
axle becomes loose. This will cause a crash with
injuries.
The quick release axle and the brake disc
must be opposite one another.
Crash caused by incorrectly set quick release
axle
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release axle may
break. This will cause a crash with injuries.
Never fasten a quick release axle with a tool,
such as a hammer or pliers.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 42
Assembly
2Tighten the axle with the red handle.
Figure 35: Tightening the axle
3Push he quick release lever into the axle.
Figure 36: Pushing the quick release lever into the axle
4Turn the quick release lever.
The lever is secured.
Figure 37: Securing the lever
5Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 38: Perfect position for the clamping lever
6Use 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
7Check the quick release lever position and
clamping force.
Figure 39: Adjusting the quick release clamping force
MY21B01 - 12_1.0_06.07.2020 43
Assembly
5.4.1.4 Quick release
Only applies to Suntour forks with quick release
1Before installing, ensure that the quick release
flange is extended. Open the lever fully.
Figure 40: Open and closed flange
2Push in the quick release until you can hear a
click. Make sure that the flange is extended.
Figure 41: Pushing the quick release in
3Adjust tensioning with half-open clamping
lever until the flange reaches the fork end.
Figure 42: Adjusting the clamping
4Fully close the quick release. Check that the
quick release is firmly in place and adjust it on
the flange if necessary.
The lever is secured.
Figure 43: Closing the quick release
Crash caused by unfastened quick release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Never fit a defective quick release.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release may break.
This will cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 44
Assembly
5.4.2 Installing the wheel in the FOX fork
5.4.2.1 Quick release (15 mm)
Only applies to FOX forks with 15 mm screw-on axle
The same procedure is used for installing both the
15 x 100 mm and 15 x 110 mm quick releases.
1Place the front wheel in the fork ends of the
fork. Push the axle through the fork end on the
non-drive side and hub.
Figure 44: Pushing the quick release in
2Open the axle lever.
3Turn the axle five to six complete revolutions
clockwise into the axle nut.
4Close the quick release lever. The lever must
be tensioned to the point that it leaves a mark
on your hand.
5The lever must be 1 to 20 mm ahead of the fork
leg in the closed position.
Figure 45: Spacing between lever and fork leg
The quick release must be adjusted if the lever
is tensioned inadequately or too strongly when
closed in the recommended position (1 to
20 mm in front of the fork).
Setting the quick releases
Figure 46: Structure of quick release from rear with (1)
axle nut lock and (5) axle nut
1Record the axle setting value (4) indicated by
the directional arrow (3).
2Loosen the axle nut securing screw (2) with a
2.5 mm hex key by approx. four revolutions,
but do not remove the screw completely.
3Turn the quick release lever to the open
position and loosen the axle by approx. four
revolutions.
4Press the axle inward from the side of the open
lever. This pushes out the axle nut securing
screw so that you can turn it out of the way.
5Push the axle further forward and turn the axle
nut clockwise to increase the lever tension or
anti-clockwise to reduce the lever tension.
6Reinsert the axle nut lock and tighten the screw
to 0.9 Nm (8 in-lb).
7Repeat the steps for installing the axle to check
proper installation and correct adjustment.
1-20 mm
1
2
3
45
MY21B01 - 12_1.0_06.07.2020 45
Assembly
5.4.2.2 Kabolt axle
Only applies to FOX forks with Kabolt axles
The same procedure is used for installing both the
15 x 100 mm and 15 x 110 mm Kabolt axles.
1Place the front wheel in the fork ends of the
fork. Push the Kabolt axle through the fork end
on the non-drive side and hub.
Figure 47: Pushing the Kabolt axle in
2Tighten the Kabolt axle screw to 17 Nm
(150 in-lb) with a 6 mm hex key.
5.4.3 Checking the stem and handlebars
5.4.3.1 Checking the connections
1Stand in front of the pedelec to check whether
the handlebars, stem and fork steerer are firmly
attached to one another. Clamp the front wheel
between your legs. Grasp the handlebar grips.
2Try to twist the handlebars towards the front
wheel.
The stem must not move or twist.
5.4.3.2 Firm hold
1Place your entire body weight on the
handlebars with the quick release lever closed
to check that the stem is firmly in place.
The handlebars shaft must not move
downwards in the fork steerer.
2If the handlebars shaft should move in the fork
steerer, increase the quick release lever
tensioning. To do so, turn the knurled nut
slightly in a clockwise direction with the quick
release lever open.
3Close the lever and check the stem is firmly in
position.
5.4.3.3 Checking the headset backlash
1To check the handlebar headset backlash,
close the quick release lever on the stem.
2Place the fingers of one hand on the upper
headset cup. Pull the front wheel brake with the
other hand and try to push the pedelec
backwards and forwards.
3The headset cup halves must not move
towards one another while you are doing this.
Note that there may be noticeable backlash
due to worn-out bearing bushes or brake lining
backlash in suspension forks and disc brakes.
4If there is headset backlash in the steering
headset, you must adjust it as soon as
possible; otherwise, the headset will become
damaged. You must make the adjustment as
described in the stem manual.
5.5 Pedelec sale
Complete Pedelec pass on the operating
instructions envelope.
Note down the battery key manufacturer and
its number.
Adjust the pedelec to the rider; see Section 6.5.
Set the stand and shifter.
Instruct the operator or rider on how to use all
the pedelec's functions.
MY21B01 - 12_1.0_25.06.2020 46
Operation
6 Operation
6.1 Risks and hazards
Injuries and death caused by other road users
Other road users, trucks, cars or pedestrians often
underestimate the speed of pedelecs. Likewise,
other road users frequently do not see pedelecs.
This may cause a crash with serious injuries or
even death.
Wear a cycling helmet and high-visibility,
reflective clothing.
Always take a defensive approach to riding.
Avoid the blind spots of vehicles turning off.
Reduce speed as a precaution when other
road users turn right.
Injuries and death caused by riding
incorrectly
A pedelec is not a bicycle. Incorrect riding and
underestimated speeds soon result in hazardous
situations. This may cause a fall with serious
injuries or even death.
If you haven't ridden on a pedelec for some
time, get accustomed to the speed first before
you ride at speeds over 12 km/h. Increase the
level of assistance gradually.
Practice braking hard on a regular basis.
Take and complete a riding safety course.
Crash caused by loose clothing
Shoe laces, scarves and other loose items may
become entangled in the spokes on the wheels
and on the chain drive. This may cause a crash
with injuries.
Wear sturdy footwear and close-fitting
clothing.
WARNING
!
CAUTION
!
Crash caused by difficult-to-spot damage
If the pedelec topples over or you have a fall or an
accident, there may be difficult-to-spot damage to
components such as the brake system, quick
releases or frame. This may cause a crash with
injuries.
Take the pedelec out of service and have a
specialist dealer carry out an inspection.
Crash caused by material fatigue
Intensive use can cause material fatigue. A
component may suddenly fail in case of material
fatigue. This may cause a crash with injuries.
Remove the pedelec from service immediately
if there are any signs of material fatigue. Have
the specialist dealer check the state.
Have the specialist dealer carry out a basic
inspection regularly. During the inspection, the
specialist dealer will inspect the pedelec for
any signs of material fatigue on the frame,
fork, suspension element mountings (if there
are any) and components made of composite
materials.
Carbon becomes brittle when exposed to heat
radiation such as heating. This can cause the
carbon part to break and result in a crash with
injuries.
Never expose carbon parts on the pedelec to
strong sources of heat.
Crash caused by soiling
Heavy soiling can impair pedelec functions, such
as braking. This may cause a crash with injuries.
Remove coarse soiling before riding.
CAUTION
!
MY21B01 - 12_1.0_25.06.2020 47
Operation
6.1.1 Personal protective equipment
It is recommended that you wear a suitable
cycling helmet, sturdy footwear and typical, close-
fitting, reflective sports clothing.
6.2 Tips for a greater range
The pedelec's range depends on many
influencing factors. A single battery charge may
only last fewer than 20 kilometres but much more
than 100 is also possible. There are a few tips
which will generally help you maximize range.
Pedalling frequency
Ride using pedalling frequencies of over
50 revolutions per minute. This optimises the
electric drive's efficiency.
Avoid pedalling very slowly.
Weight
Minimise the total weight of pedelec and
baggage.
Stopping and starting
Ride long distances at a constant speed.
Avoid stopping and starting frequently.
Gear shift
Use a low gear and a low level of assistance on
hills and when setting off.
Switch up a gear depending on the speed and
terrain.
Follow the gear recommendations on the
display screen.
Tyre pressure
Always use the maximum permitted tyre
pressure.
Motor power indicator
Adjust your riding to the displayed motor
power. A long bar indicates high power
consumption.
Battery and temperature
Electrical resistance increases as the temperature
drops. Battery performance is reduced. As a
result, you should expect the range to be shorter
than normal in winter.
Use a thermal protection sleeve on the battery
in winter.
Crash caused by poor road conditions
Loose objects, such as branches and twigs, may
become caught in the wheels and cause a crash
with injuries.
Be aware of the road conditions.
Ride slowly and brake in good time.
Notice
Heat or direct sunlight can cause the tyre pressure
to increase above the permitted maximum
pressure. This can destroy the tyres.
Never park the pedelec in the sun.
On hot days, regularly check the tyre pressure
and adjust it as necessary.
When riding downhill, high speeds may be reached.
The pedelec is only designed to exceed a speed of
25 km/h for short intervals. The tyres in particular
can fail if exposed to a continuous load.
Use the brakes to decelerate the pedelec
if you reach speeds greater than 25 km/h.
Notice
Moisture penetrating at low temperatures may
impair individual functions due to the open
structural design.
Always keep the pedelec dry and free from
frost.
If the pedelec is to be used at temperatures
below 3 °C, the specialist dealer must carry
out an inspection and prepare it for winter use.
Off-road riding subjects the joints in the arms to
severe strain.
Take a break from riding every 30 to
90 minutes, depending on the road surface
conditions
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 48
Operation
6.3 Error message
6.3.1 Display
The drive system monitors itself continuously and
displays a number as an error message if a known
error is detected. The system may switch off
automatically depending on the type of error.
Code Description Method of resolution
410 One or more display
buttons are blocked
Check whether buttons are
jammed because dirt has
accumulated between them,
for example.
Clean buttons if necessary.
414 Control panel connection
problem
Contact specialist dealer.
Have ports and connections
checked.
418 One or more buttons on
the control panel are
blocked
Check whether buttons are
jammed because dirt has
accumulated between them,
for example.
Clean buttons if necessary.
419 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
422 Battery connection
problem
Have ports and connections
checked.
423 Battery connection
problem
Have ports and connections
checked.
424 Communication error with
components
communicating with one
another
Have ports and connections
checked.
426 Internal time-out error It is not possible to display or
adjust the tyre size in the basic
settings menu in this error status.
1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
430 Display battery flat Recharge display battery
(while in its mount or using
USB port).
431 Software version error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
440 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
450 Internal software error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
460 Error in USB port 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
Table 47: List of display screen error messages
490 Internal display error Have display checked.
500 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
502 Fault in the lighting 1Check the light and its
cabling.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
503 Speed sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
504 Speed signal manipulation
detected
Check position of spike
magnets and re-adjust if
necessary.
Check for manipulation.
Assistance from drive has
been reduced.
503 Speed sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
510 Internal sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
511 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
530 Battery error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start electric drive
system.
5Contact your specialist
dealer if the problem
persists.
531 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
540 Temperature error
The pedelec is outside the
permitted temperature
range.
1Switch off the system to cool
the motor and battery down
or warm them to the
permitted temperature
range.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
550 An inadmissible electrical
load has been detected 1Remove consumer.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 47: List of display screen error messages
MY21B01 - 12_1.0_06.07.2020 49
Operation
580 Software version error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
591 Authentication error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start the system.
5Contact your specialist
dealer if the problem
persists.
592 Incompatible component 1Insert a compatible display.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
593 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
595, 596 Communication error 1Check cabling to the gears.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
602 Internal error during
charging 1Disconnect charger from
battery.
2Re-start the system.
3Connect charger to the
battery.
4Contact your specialist
dealer if the problem
persists.
602 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
603 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
605 Temperature error
The pedelec is outside the
permitted temperature
range.
1Switch off the system to cool
the motor and battery down
or warm them to the
permitted temperature
range.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
605 Temperature error during
the charging process 1Disconnect charger from
battery.
2Leave battery to cool down.
3Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 47: List of display screen error messages
606 External fault 1Check the cabling.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
610 Voltage error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
620 Charger error 1Replace charger.
2Contact your specialist
dealer if the problem
persists.
640 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
655 Multiple battery error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start the system.
5Contact your specialist
dealer if the problem
persists.
656 Software version error Contact your specialist
dealer to install a software
update.
7xx Gear error Please observe the gear
manufacturer's operating
instructions.
800 Internal ABS error Contact your specialist
dealer.
810 Implausible signals from
the wheel speed sensor
Contact your specialist
dealer.
820 Error in the line to the front
wheel speed sensor
Contact your specialist
dealer.
821 ...
826 Implausible signals from
the front wheel speed
sensor.
It is defective or incorrectly
installed; significantly
different tyre diameter
between the front wheel
and rear wheel; extreme
riding, such as riding on
the rear wheel only
1Re-start the system.
2Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
3Contact your specialist
dealer if the problem
persists.
830 Error in the line to the rear
wheel speed sensor
Contact your specialist
dealer.
831
833 ...
835
Implausible signals from
the rear wheel speed
sensor.
Sensor disc may be
missing. It is defective or
incorrectly installed;
significantly different tyre
diameter between the
front wheel and rear
wheel; extreme riding,
such as riding on the rear
wheel only
1Re-start the system.
2Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
3Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 47: List of display screen error messages
MY21B01 - 12_1.0_06.07.2020 50
Operation
6.3.2 Rechargeable battery
The battery is protected against deep discharge,
overcharging, overheating and short circuits by
Electronic Cell Protection (ECP). In the event of a
hazard, a protective circuit switches the battery off
automatically.
If a fault is detected in the battery, the LEDs flash
on the battery level indicator.
840 Internal ABS error Contact your specialist
dealer.
850 Internal ABS error Contact your specialist
dealer.
860, 861 Error in the power supply 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
870, 871,
880
883..
885
Communication error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
889 Internal ABS error Contact your specialist
dealer.
890 ABS indicator lamp is
defective or missing; ABS
possibly not functioning
Contact your specialist
dealer.
No
screen
display
Internal display error Re-start the drive system by
switching it on and off.
Code Description Method of resolution
Table 47: List of display screen error messages
Code Description Method of resolution
If the battery is outside its
charging temperature
range, three LEDs will
flash on the battery level
indicator.
1Disconnect charger from
battery.
2Leave battery to cool down.
3Contact your specialist
dealer if the problem
persists.
If a fault is detected in the
battery, two LEDs flash on
the battery level indicator.
Contact your specialist
dealer.
No LEDs will flash if the
charger is defective and
will not charge. One or
more LEDs will light up
permanently, depending
on the battery level.
Contact your specialist
dealer.
No LEDs will light up if
there is no power. 1Check all plug connections.
2Check the contacts on the
battery for dirt. Clean the
contacts carefully if needed.
3Contact your specialist
dealer if the problem
persists.
Table 48: List of battery error messages
MY21B01 - 12_1.0_25.06.2020 51
Operation
6.4 Instruction and customer service
Your supplying specialist dealer will provide
customer service. Contact details can be found on
the pedelec pass for these operating instructions.
The specialist dealer will explain all the pedelec
functions to you in person, this being when the
specialist dealer hands over the pedelec at the
latest. These operating instructions are provided
to you with every pedelec, so that you can consult
them at a later stage.
Your specialist dealer will also be happy to assist
you in the future whether you require
maintenance, conversion or repair.
6.5 Adjusting the pedelec
Only a correctly adjusted pedelec will guarantee
the desired ride comfort and health-promoting
activity. Therefore adjust the saddle, the
handlebars and the suspension to your body and
your preferred riding style before the first ride.
6.5.1 Adjusting the saddle
6.5.1.1 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.
First adjust the handlebars, then the saddle.
Adjust the saddle tilt to horizontal.
Figure 48: Horizontal saddle tilt
6.5.1.2 Determining the seat height
To adjust the seat height safely, either
push the bike near to a wall, so that the rider can
lean on the wall to support themselves or
ask another person to hold the pedelec.
1Climb onto the bicycle.
2Place your heel on the pedal and extend your
leg, so that the pedal is at the lowest crank
rotation point.
The rider sits straight on the saddle if the seat
is at an optimum height. If this is not the case,
adjust the length of the seat post to your
needs.
Figure 49: Optimal saddle height
Crash caused by incorrectly adjusted torques
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.
Always observe the indicated torques on the
screw or in the operating instructions.
CAUTION
!
MY21B01 - 12_1.0_25.06.2020 52
Operation
6.5.1.3 Adjusting the seat height with quick
release
1Open the quick release on the seat post to
change the seat height (1). To do so, push the
clamping lever away from the seat post (3).
Figure 50: Opening the seat post quick release
2Set the seat post to the required height.
Figure 51: Detailed view of the seat post – examples of the
minimum insertion depth marking
3To close it, push the seat post clamping lever as
far as it will go into the seat post (2).
4Check the clamping force of quick releases.
6.5.1.4 Adjusting the seat 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.
To adjust the seat position safely, either push the
pedelec near to a wall, so that you can lean on the
wall to support yourself or ask another person to
hold the pedelec for you.
1Climb onto the bicycle.
2Place the pedals into the vertical position with
your feet.
The rider is sitting in the optimal sitting position if
the perpendicular line from the kneecap runs
through the pedal axle.
3.1If the perpendicular line crosses behind the
pedal, bring the saddle further forward.
3.2If the perpendicular line crosses in front of the
pedal, bring the saddle further back.
4Move the saddle within its permitted
displacement range only (marked on the
saddle stay).
Figure 52: Knee cap perpendicular line
Crash caused by an excessively high seat post
setting
A seat post with is set too high will cause the seat
post or the frame to break. This will cause a crash
with injuries.
Do not pull the seat post out of the frame
beyond the minimum insertion depth marking.
3
4
5
1
2
3
CAUTION
!
3
4
2
1
The handlebar settings must only be adjusted
while the bicycle is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the
maximum tightening torque for the clamping
screws of the handlebars.
90°
MY21B01 - 12_1.0_25.06.2020 53
Operation
6.5.2 Adjusting the handlebars
6.5.3 Adjusting the stem
6.5.3.1 Adjusting the height of the handlebars
1Open the stem clamping lever.
Figure 53: Open (2) and closed (1) stem clamping lever; All
Up used as an example
Figure 54: Pulling the locking lever upwards; All Up used
as an example
2Pull out the handlebars to the required height.
Observe minimum insertion depth.
3Close the stem clamping lever.
6.5.3.2 Adjusting the quick release clamping
force
If the handlebar clamping lever stops before
reaching its end position, unscrew the knurled
nut.
Tighten the knurled nut on the seat post if the
seat post clamping lever's clamping force is not
effective enough.
If you are unable to set the clamping force, the
specialist dealer will need to check the quick
release.
6.5.4 Retracting the brake linings
Disc brakes require wearing-in time. The braking
force increases over time. You therefore need to be
aware that the braking force may increase during the
wearing-in period. The same happens after brake
pads or discs are replaced.
1Accelerate pedelec to about 25 km/h.
2Brake pedelec until it comes to a halt.
3Repeat process 30–50 times.
The disc brake is retracted and provides
optimal braking power.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
Crash caused by loose stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the quick release
system are firmly in position after the first two
hours of riding.
CAUTION
!
CAUTION
!
1
2
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Operation
6.5.5 Adjusting the Suntour fork
Only applies to pedelecs with this equipment
The adjustment shown here represents a basic
setting. The rider should change the basic setting
to suit the surface and his/her preferences.
It is advisable to make a note of the basic
setting. This way, it can be used as the starting
point for subsequent, optimised settings and to
safeguard against unintentional changes.
6.5.5.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection is between 15% (hard) and 30% (soft)
of the total fork deflection.
6.5.5.2 Adjusting the steel suspension fork
negative deflection
Only applies to pedelecs with this equipment
You can adjust the tensioning in the fork spring to
the rider's weight and their preferred riding style.
This reduces the negative deflection in the fork.
Figure 55: Negative deflection setting wheel on the
suspension fork crown
1You will find the negative deflection setting
wheel beneath the plastic cover on the crown.
Remove the plastic cover.
Turn the negative deflection setting wheel in a
clockwise direction to increase the spring pre-
tensioning.
Turn the negative deflection setting wheel in
an anti-clockwise direction to decrease the
spring pre-tensioning.
You will have made the ideal setting if the
shock absorber deflects 3 mm when bearing
the rider's weight.
2Replace the plastic cover on the crown after
making the setting.
Crash caused by incorrectly set suspension
If the suspension is set incorrectly, the fork may
become damaged, meaning problems may occur
when steering. This will cause a crash with
injuries.
Never ride the bicycle without air in the air
suspension fork.
Never use the pedelec without adjusting the
suspension fork to the rider's weight.
Notice
Settings on the chassis change riding
performance significantly. You need to get used
to the bicycle and break it in to prevent accidents.
CAUTION
!
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Operation
6.6 Accessories
We recommend a parking stand into which either
the front wheel or rear wheel can be inserted
securely for pedelecs which do not have a
kickstand. The following accessories are
recommended:
*System components are matched to the pannier
rack and provide sufficient stability due to special
transmission of force.
**System components are matched to the drive
system.
6.6.1 Child seat The specialist dealer will advise you on choosing
a suitable child seat system for the child and the
pedelec.
The specialist dealer must install the child seat the
first time to ensure that it is safely fitted.
When installing a child seat, the specialist dealer
makes sure that the seat and the fastening
mechanism for the seat are suitable for the
pedelec and that all components are installed and
firmly fastened. They will also ensure that shift
cables, brake cables, hydraulic lines and electrical
cables are adjusted as necessary, the rider has
optimum freedom of movement and the pedelec's
maximum permitted total weight is complied with.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
Description Article number
Protective cover for electrical
components 080-41000 ff
Panniers,
system component* 080-40946
Rear wheel basket,
system component* 051-20603
Bicycle box,
system component* 080-40947
Parking stand
universal stand XX-TWO14B
Table 49: Accessories
Crash caused by incorrect child seat
The pannier rack and down tube are unsuitable
for mounting child seats and may break. Such an
incorrect position may cause a crash with serious
injuries for the rider and the child.
Never attach a child seat to the saddle,
handlebars or down tube.
Crash caused by improper handling
When using child seats, the pedelec's handling
characteristics and stability change considerably.
This can cause a loss of control, a crash and
injuries.
You should practice how to use the child seat
safely before using the pedelec in public
spaces.
WARNING
!
CAUTION
!
Risk of crushing due to exposed springs
The child may crush his/her fingers on exposed
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.
Never install seat posts with suspension with
open mechanical parts or exposed springs if a
child seat is being used.
Notice
Observe the legal regulations on the use of
child seats.
Observe the operating and safety instructions
for the child seat system.
Never exceed the maximum permitted total
weight.
CAUTION
!
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Operation
6.6.2 Trailer
A pedelec which is approved for towing a trailer
will bear an appropriate adhesive label. You may
only use trailers with a tongue load and weight
which do not exceed the permitted values.
Figure 56: Trailer sign
The specialist dealer will advise on choosing a
suitable trailer system for the pedelec. The
specialist dealer must install the trailer the first
time to ensure that it is safely fitted.
6.6.3 Pannier rack
The specialist dealer will advise on choosing a
suitable pannier rack.
The specialist dealer must install the pannier rack
the first time to ensure that it is safely fitted.
When installing a pannier rack, the specialist
dealer makes sure that the fastening mechanism
is suitable for the pedelec and that all components
are installed and firmly fastened. They will also
ensure that shift cables, brake cables, hydraulic
lines and electrical cables are adjusted as
necessary, the rider has optimum freedom of
movement and the pedelec's maximum permitted
total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the pannier rack.
Crash caused by brake failure
The braking distance may be longer if the trailer
is carrying excessive load. The long braking
distance can cause a crash or an accident and
injuries.
Never exceed the specified trailer load.
Notice
The operating and safety instructions for the
trailer system must be observed.
The statutory regulations on the use of bicycle
trailers must be observed.
Only use type-approved coupling systems.
CAUTION
!
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Operation
6.7 Check list before each ride
Check the pedelec before each ride.
Take the pedelec out of service if you spot any
anomalies.
Check that the pedelec is complete.
Check the battery is firmly in place.
Check that the lighting, reflector and brake, for instance,
are sufficiently clean.
You must check that the mudguards, the pannier rack and
the chain guard are securely installed.
Check that the front and rear wheels run true. This is
particularly important if the pedelec been transported or
secured with a lock.
Check the valves and the tyre pressure. Adjust as
necessary before each ride.
If the bicycle has a hydraulic rim brake, check whether the
locking levers are fully closed in their final positions.
Check the front and rear wheel brakes to make sure that
they are working properly. To do so, push the brake levers
while stationary to check whether resistance is generated
in the usual brake lever position. The brake must not lose
any brake fluid.
Check that the riding light is working.
Check for unusual noises, vibrations, smells, staining,
deformation, cracks, scores, abrasion and wear. This
indicates material fatigue.
Inspect suspension system for cracks, dents, bumps, parts
or leaking oil. Look at concealed sections on the pedelec's
lower surface.
If quick releases are used check them to make sure that
they are fully closed in their end position.
Be alert to any unusual operating sensations when braking,
pedalling or steering.
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Operation
6.8 Using the kickstand
6.8.1 Raising the kickstand
Use your foot to raise the kickstand completely
before setting off.
6.8.1.1 Parking the pedelec
Use your foot to lower the kickstand completely
before parking.
Park the pedelec carefully and check that it is
stable.
6.9 Using the pannier rack
Distribute the baggage as evenly as possible
between the left- and right-hand side.
We recommend the use of panniers and
baggage baskets.
Crash caused by a lowered kickstand
There is a risk of crashing if riding with the
kickstand lowered.
Raise the kickstand completely before setting
off.
Notice
The pedelec's force of weight may cause the
kickstand to sink into soft ground, possible
causing the pedelec to topple over as a result.
The pedelec must be parked on firm, level
ground only.
It is particularly important to check that the
pedelec is stable if it is equipped with
accessories or loaded with baggage.
Crash caused by loaded pannier rack
The pedelec is handled differently with a loaded
pannier rack, in particular when the rider needs to
steer and brake. This can lead to a loss of control.
This may cause a crash with injuries.
You should practice how to use a loaded
pannier rack safely before using the pedelec in
public spaces.
CAUTION
!
CAUTION
!
Crash caused by unsecured baggage
Loose or unsecured objects on the pannier rack,
e.g. belts, may become caught in the rear wheel.
This may cause a crash with injuries.
Objects which are fastened to the pannier rack
may cover the reflectors and the riding light. Other
users may not see the pedelec on public roads as
a result. This may cause a crash with injuries.
Secure any objects which are attached to the
pannier rack sufficiently.
Objects fastened to the pannier rack must
never cover the reflectors, the headlight or the
rear light.
Crushing the fingers in the spring flap
The spring flap on the pannier rack operates with
a high clamping force. There is a risk of crushing
the fingers.
Never allow the spring flap to snap shut in an
uncontrolled manner.
Be careful where you position your fingers
when closing the spring flap.
Notice
The maximum load bearing capacity is indicated
on the pannier rack.
Never exceed the maximum permitted total
weight when packing the pannier.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
CAUTION
!
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Operation
6.10 Rechargeable battery
Switch off the battery and the drive system before
removing or inserting the battery.
6.10.1 Frame battery
Only applies to pedelecs with this equipment
6.10.1.1 Removing the frame battery
Figure 57: Removing and inserting the frame battery
1Open battery lock with battery key (see (1)).
2Tip the battery out of the top section of the
frame battery mount.
3Pull battery from the frame battery mount
(see (2)).
6.10.1.2 Inserting the frame battery
1Place the battery on the contacts in the lower
section of the frame battery mount (see (3)).
2Remove the battery key from the battery lock
(see (4)).
3Tip the battery into the top section of the frame
battery mount until it will go no further.
There is an audible clicking noise.
4Check the battery to make sure it is firmly in
place.
6.10.2 Pannier rack battery
Only applies to pedelecs with this equipment
6.10.2.1 Removing the pannier rack battery
Figure 58: Removing (2) and inserting (3) the pannier rack
battery
1Open battery lock with battery key (see (1)).
2Pull the pannier rack battery backwards and
out of its mount (see (2)).
3Remove the battery key from the battery lock
(see (1)).
6.10.2.2 Inserting the pannier rack battery
1Insert the pannier rack battery into its mount
with the contacts facing the front until it clicks
into place (see (3)).
2Check the battery to make sure it is firmly in
place.
(2)
(1)
(3)
(4)
(1) (2)
(3)
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Operation
6.10.3 Integrated battery
Only applies to pedelecs with this equipment
6.10.3.1 Removing the integrated battery
Figure 59: Removing the integrated battery
1Open battery lock with battery key (see (1)).
The battery is released and falls into the
retainer guard (see (2)).
2Hold the battery in your hand from below. Use
the other hand to push on the retainer guard
from above (see (3)).
The battery is released and falls into the hand
(see (4)).
3Remove the battery from the frame.
4Remove the battery key from the battery lock.
6.10.3.2 Inserting the integrated battery
Figure 60: Inserting the integrated battery
1Place the battery into the lower mount with the
contacts facing the front (see (1)).
2Flip the battery up so that the battery is held by
the retainer guard (see (2)).
3Push the battery upwards (see (3)).
There is an audible clicking noise.
4Check battery to ensure it is firmly in place.
5Lock the battery with the battery key;
otherwise, the battery may fall out of the mount
when you open the lock (see (4)).
6Remove the battery key from the battery lock.
7Check the battery to ensure it is firmly in place.
(1)
(2)
(3)
(4)
(1)
(2) (3)
(4)
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Operation
6.10.4 Charging the battery
The ambient temperature during the charging
process must be within the range from 0 °C to
40 °C.
The battery can remain on the pedelec or can be
removed for charging.
Interrupting the charging process does not
damage the battery.
1Remove the cable connection cover if
necessary.
2Connect the mains plug of the charger to a
normal domestic, grounded socket.
3Connect the charging cable to the battery's
charging port.
The charging process starts automatically.
The battery level indicator shows the charge
level during charging. When the drive system is
switched on, the display screen shows the
charging process.
The charging process is complete when the
LEDs on the operating status and battery level
indicator go out.
4Once charging is complete, disconnect the
battery from the charger.
5Disconnect the charger from the mains.
6.10.5 Charging the dual battery
Only applies to pedelecs with this equipment.
6.10.5.1 Charging process when two batteries
are used
If two batteries are attached to a pedelec,
charge both batteries via the non-sealed
socket.
The two batteries are charged alternately
during charging. Charging switches
automatically between the two batteries
several times. The charging time is twice as
long.
The two batteries are discharged alternately
during use.
Fire caused by overheated charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in
fire or burns to the hands.
Never use the charger on a highly flammable
surface (e.g. paper, carpet etc.).
Never cover the charger during the charging
process.
Never leave battery unattended during
charging.
Electric shock caused by penetration by
water
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
Electric shock in case of damage
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
Notice
If an error occurs during the charging process, a
system message is displayed.
Remove the charger and battery from
operation immediately and follow the
instructions.
Connection data 230 V, 50 Hz
CAUTION
!
Notice
Check that mains voltage! The power source
voltage must match the voltage indicated on
the charger nameplate. Chargers labelled
230 V may be operated at 220 V.
Notice
Charge the battery via the accessible charging
socket only.
Never open a sealed charging socket.
Charging via a pre-closed charging socket can
cause irreparable damage
MY21B01 - 12_1.0_25.06.2020 62
Operation
6.10.5.2 Charging process when one battery
is used
Remove the batteries from their mounts to
charge each one individually.
If only one battery is inserted, only charge the
battery with an accessible charging socket.
The battery with the sealed charging socket
can only be charged outside its mount.
6.10.6 Using double battery model with a
single battery only
One of the charging sockets is not accessible or is
sealed with an end cap on pedelecs with two
batteries
Figure 61: Covering open contacts with cover cap –
example: pannier rack battery
If you wish to use just one battery on a pedelec
which is designed for two batteries, cover the
contacts in the free slot with the supplied cover
cap (see (1)); otherwise, there is a risk of a
short circuit caused by the open contacts.
6.10.7 Waking the battery
The battery switches to sleep mode to protect
itself when not used for a longer period. The LEDs
on the operating status and battery level indicator
do not light up.
Press the On-Off button (battery).
The operating status and battery level indicator
shows the battery level.
(1)
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Operation
6.11 Electric drive system
6.11.1 Switching on the electric drive
system
A sufficiently charged battery has been inserted
into the pedelec.
The battery is firmly positioned. The battery key
has been removed.
There are three options for switching on the drive
system.
On-Off button (battery)
Press the On-Off button (battery) briefly.
On-Off button (display)
Press the On-Off button (display) briefly.
Switched-on display
If the display is already switched on when it is
inserted into its mount, the electric drive
system is switched on automatically.
After switching on, a speed of 0 KM/H is
displayed on the display. If it is not, check
whether the display screen is fully engaged into
position.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force (except if in push assist mode
or the level of assistance is "OFF").
The motor power is determined by the level of
assistance set on the display.
As soon as the system has been activated,
ACTIVE LINE/PERFORMANCE LINE
appears briefly on the display.
6.11.2 Switching off the drive system
As soon as you stop pushing the pedals in normal
mode or reach a speed of 25 km/h, the drive
system switches off the assistance system. The
assistance system starts up again if you push the
pedals and your speed is less than 25 km/h.
The system switches off automatically ten minutes
after the last command. There are three options
for switching off the drive system manually.
On-Off button (display)
Press the On-Off button (display) briefly.
On-Off button (battery)
Press the On-Off button (battery).
Removing the display
Remove the display from the mount.
The LEDs on the operating status and battery
level indicator go out.
Crash caused by lack of readiness for braking
When it is switched on, the drive system can be
activated by the application of force on the
pedals. There is a risk of a crash if the drive is
activated unintentionally, and the brake is not
reached.
Never start the electric drive system, or switch
it off immediately, if the brake cannot be
reached safely and reliably.
CAUTION
!
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Operation
6.12 Control panel with display
6.12.1 Removing and attaching the display
The system is switched off by removing the
display.
6.12.1.1 Removing the display
Push the display catch down and
simultaneously push the display forwards and
out of the mount.
6.12.1.2 Attaching the display
1Place the display on the mount.
2Push the display back as far as it will go.
Figure 62: Push display (2) over the display catch (1) until
it locks into the mount (3)
6.12.2 Securing the display against
removal
1Detach the display mount from the handlebars.
2Place display in its mount.
3Fasten the blocking screw (M3 thread, 8 mm in
length) into its designated thread in the mount
from below.
4Fit the mount to the handlebars.
The display is secured against removal.
6.12.3 Charging the display battery
If the display battery is low when you switch on
the display, ATTACH TO PEDELEC appears
on the text display for three seconds. The display
then switches back off.
There are two options for charging the battery.
Crash caused by distraction
A lack of concentration while riding increases the
risk of an accident. This may cause a crash with
serious injuries.
Never allow yourself to be distracted by the
display.
Stop bicycle if you want to make inputs on the
display other than a change in level of
assistance. Only enter data when the bicycle
is stationary.
Notice
Do not use display as a handle. The display
may become irreparably damaged if you use it
to lift the pedelec.
If you do not use your bicycle for several
weeks, remove the display from its mount.
Store the display safely at room temperature in
a dry environment.
The internal display battery discharges when it is
not in use. This can cause damage to the internal
display battery.
Charge the internal display battery every
3 months for at least 1 hour.
Notice
If the rider is not present, the display can be used
without authorisation, e.g. it may be stolen, the
system settings may be changed or journey
information may be read.
Remove display when you park.
CAUTION
!
Notice
The display battery discharges when it is not in
use. This can cause irreparable damage to the
display battery.
Recharge the display battery for at least
1 hour every 3 months.
ECO
MPH
KM/H
Reichweite
KM /H
RESET
EC O
MPH
KM/H
Reichweite
KM
/H
1
2
3
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Operation
6.12.3.1 Charging on the pedelec
1Once a battery has been inserted into the
pedelec, place the display in the display mount.
Press the On-Off button (battery).
2Using the pedelec
6.12.3.2 Charging using the USB port
1Open the protective flap on the USB port.
2Connect the USB port to a commercially
available USB charger or the USB port on a
computer (5 V charge voltage; max. 500 mA
charging current), using a suitable USB cable.
USB CONNECTED is displayed on the
display.
6.12.4 Using the USB port
The USB port can be used to operate external
devices which can be connected using a standard
micro A/micro B USB 2.0 cable.
1Open the protective flap on the USB port.
2Replace the protective flap after using the USB
port.
6.12.5 Switching on the display
Press the On-Off button (display) briefly.
The electric drive system is switched on.
6.12.6 Switching off the display
If the display is not inserted into the mount, it will
switch off automatically after one minute to save
energy if no button is pressed.
Press the On-Off button (display) briefly.
The electric drive system is switched off.
6.12.7 Using the push assist system
The push assist provides the rider with assistance
when they are pushing the pedelec. The speed
can be a maximum of 6 km/h in this case.
The tractive power of the push assist and its
speed can be influenced by the selection of gear.
To spare the drive, first gear is recommended for
travelling uphill.
The level of assistance OFF must not be
selected.
1Press the push assist button briefly.
2Press and hold the plus button within 3
seconds to switch on the push assist.
3Release the plus button to shut off the push
assist. The push assist system switches off
automatically as soon as the wheels are
blocked or the speed exceeds 6 km.
6.12.8 Using the riding light
The drive system needs to be already switched
on to turn on the riding light.
Press the riding light button.
The riding light is switched on (riding light
symbol is displayed) or switched off (riding
light symbol is not displayed).
Notice
Any moisture penetrating through the USB port
may trigger a short circuit in the display.
Regularly check the position of the rubber
cover on the USB port and adjust it as
necessary.
Injury from pedals or wheels
The pedals and the drive wheel turn when the
push assist system is used. There is a risk of
injury if the wheels are not in contact with the
ground when the push assist system is used (e.g.
when carrying the pedelec up stairs or when
placing it on a bicycle rack).
Only use the push assist mode when pushing
the pedelec.
You must steer the pedelec securely with both
hands when using push assist.
Allow for enough freedom of movement for the
pedals
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 66
Operation
6.12.9 Selecting the level of assistance
Press the plus button to increase the level of
assistance.
Press the minus button to reduce the level of
assistance.
6.12.10 Journey information
The displayed journey information can be
changed and partially reset.
If the display is removed from its mount, all
function values are saved and can still be
displayed.
6.12.10.1Switching the displayed journey
information
Press the info button (display) or info button
(operating element) repeatedly until the
required journey information is displayed.
6.12.10.2Resetting the journey information
If you wish to reset the Trip Distance, Trip
Time and Avg. Speed switch to one of these
three functions. Press the RESET button until
the indicator is set to zero. This will also reset
the readings for the other two functions.
If you wish to reset the Max. speed journey
information, switch to this function. Press the
RESET button until the indicator is set to zero.
If you wish to reset the Range journey
information, switch to this function. Press the
RESET button until the indicator is the factory
setting value.
6.12.11 Changing the system settings
The System settings can be displayed and
changed no matter whether the display is inserted
in the mount or not. A few settings are only visible
and changeable if the display is inserted. A few
menu options may be missing, depending on the
equipment used.
Press the Info button (display) and the RESET
button together.
SETTINGS is displayed on the display. The
System settings is opened.
Press the info button (display) repeatedly until
the system setting which you wish to change is
displayed.
Press the plus button or the minus button to
change the displayed setting.
Press and hold the RESET button for 3
seconds to save the changed system settings
and return to the journey information.
indicator Change
- CLOCK + You can set the current time. If you
press on the setting buttons for a
longer period of time, you can
change the time more quickly.
- WHEEL CIRCUM + You can change the value that the
manufacturer pre-set by ± 5%.
This menu option is only shown
when the display is positioned in its
mount.
- ENGLISH + You can change the language for
on-screen messages. You can
choose between English, German,
French, Dutch, Spanish, Danish,
Swedish, Italian and Portuguese.
- UNIT KM/MI + You can choose whether the
speed and distance are displayed
in kilometres or miles.
- TIME FORMAT + You can display the time in 12-
hour clock or 24-hour clock format.
- SHIFT RECOM.OFF + You can turn the gear
recommendation indicator on or
off.
Table 50: Changing the system settings
MY21B01 - 12_1.0_25.06.2020 67
Operation
6.13 Brake
The drive force of the motor is shut off during the
ride as soon as the rider no longer pedals. The
drive system does not switch off when braking.
In order to achieve optimum braking results, do
not pedal while braking.
Crash caused by brake failure
Oil or lubricant on the brake disc in a disc brake
or on the rim of a rim brake can cause the brake
to fail completely. This may cause a crash with
serious injuries.
Never allow oil or lubricant to come into
contact with the brake disc or brake linings or
on the rim of a rim brake.
If the brake linings have come into contact with
oil or lubricant, contact a dealer or a workshop
to have the components cleaned or replaced.
If the brakes are applied continuously for a long
time (e.g. while riding downhill for a long time),
the fluid in the brake system may heat up. This
may create a vapour bubble. This will cause air
bubbles or any water contained in the brake
system to expand. This may suddenly make the
lever travel wider. This may cause a crash with
serious injuries.
Release the brake regularly when riding
downhill for a longer period of time.
Amputation due to rotating brake disc
The brake disc in disc brakes is so sharp that it
can cause serious injuries to fingers if they are
inserted into the brake disc openings.
Always keep fingers well away from the
rotating brake discs.
Burns caused by heated brake
The brakes may become very hot during
operation. There is a risk of burns or fire in case
of contact.
Never touch the components of the brake
directly after the ride.
WARNING
!
CAUTION
!
Crash caused by wet conditions
The tyres may slip on wet roads. In wet conditions
you must also expect a longer braking distance.
The braking sensation differs from the usual
sensation. This can cause loss of control or a
crash, which may result in injuries.
Ride slowly and brake in good time.
Crash caused by incorrect use
Handling the brake improperly can lead to loss of
control or crashes, which may result in injuries.
Shift your body weight backwards and down as
far as possible.
Practice braking and emergency braking
before using the pedelec in public spaces.
Never use the pedelec if you can feel no
resistance when you grip the brake handle.
Consult a specialist dealer.
Crash after cleaning or storage
The brake system is not designed for use on a
pedelec which is placed on its side or turned
upside down. The brake may not function
correctly as a result. This can cause a crash,
which may result in injuries.
If the pedelec is placed on its side or turned
upside down, apply the brake a couple of times
before setting off to ensure that it works as
normal.
Never use the pedelec if the brake does not
work properly. Consult a specialist dealer.
CAUTION
!
MY21B01 - 12_1.0_25.06.2020 68
Operation
6.13.1 Using the brake lever
Figure 63: Front (2) and rear (1) brake lever – Shimano
brake used as an example
Push the left-hand brake lever to apply the front
wheel brake.
Push the right-hand brake lever to apply the rear
wheel brake.
Turn the setting wheel in an anti-clockwise
direction to increase the rebound speed.
Turn the setting wheel in a clockwise direction
to decrease the rebound speed.
1
2
MY21B01 - 12_1.0_06.07.2020 69
Operation
6.14 Suspension and damping
6.14.1 Adjusting the compression in the
Suntour fork
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the fork to suit changes in terrain. It
is intended for adjustments made during the ride.
Figure 64: Suntour compression adjuster with OPEN (1)
and LOCK (2) positions
Compression damping is lowest in the OPEN
position, making the fork feel softer.
Use the lock position if you want the fork to feel
stiffer and you are riding on soft ground.
The positions between OPEN and LOCK
provide fine adjustment of compression
damping.
We recommend setting the compression adjuster
to the OPEN position first.
The compression damper controls the speed at
which the rear frame damper deflects during slow
impact, such as smaller impacts or when the rider
goes round a corner or shifts their weight. The
compression damper improves control and
efficiency.
If the compression damper is set too high,
suspension is too hard when exposed to impacts.
The damper lever is used to set the compression
damper.
Turn the setting wheel in a clockwise
direction (+) to decrease the deflection speed.
1
2
MY21B01 - 12_1.0_25.06.2020 70
Operation
6.15 Gear shift
The selection of the appropriate gear is a
prerequisite for a physically comfortable ride and
making sure that the electric drive system
functions properly. The ideal pedalling frequency
is between 70 and 80 revolutions per minute.
Stop pedalling briefly when changing gears.
This makes it easier to switch gears and
reduces wear on the drivetrain.
6.15.1 Using the derailleur gears
Only applies to pedelecs with this equipment
The speed and range can be increased while
applying the same force if you select the right
gear. Use the derailleur gears.
Figure 65: Down shifter (1) and up shifter (2) on the left (I)
and right (II) gear shift
Select the appropriate gear with the shifter.
The gear shift switches the gear.
The shifter returns to its original position.
Clean and lubricate the rear derailleur if gear
changes block.
III
1
22
1
MY21B01 - 12_1.0_25.06.2020 71
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
Servicing measures must be performed regularly.
Contact your specialist dealer if you are unsure.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits from the stanchions
and deflector seals with a damp cloth.
Check the stanchions for dents, scratches,
staining or leaking oil.
Lubricate the dust seals and stanchions.
7.1.2 Cleaning the pedals
Clean with a brush and soapy water after riding
through dirt or rain.
Service the pedals after cleaning.
Clean the pedals after each ride
Suspension fork after each ride
Cleaning the battery once a month
Chain every
250–300 km
Basic cleaning and preservation of all
components at least every six
months
Clean the charger at least every six
months
Check USB rubber cover position before each ride
Check for tyre wear once a week
Check for rim wear once a week
Check tyre pressure once a week
Check brakes for wear once a month
Check electrical cables and Bowden
cables for damage and ensure they are
fully functional once a month
Check chain tension once a month
Check tension of the spokes every three
months
Check the gear shift setting every three
months
Check the suspension fork for wear and
ensure it is fully functional every three
months
Check for wear on brake discs at least every six
months
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before cleaning.
CAUTION
!
Required tools and cleaning agents:
Cloth
•Air pump
•Brush
Water
Dish-washing liquid
•Bucket
MY21B01 - 12_1.0_25.06.2020 72
Cleaning and servicing
7.2 Basic cleaning
Remove battery and display before thorough
cleaning.
7.2.1 Cleaning the frame
1Soak the entire frame with dish-washing
detergent if the dirt is thick and ingrained.
2After leaving it to soak for a short time, remove
the dirt and mud with a sponge, brush and
toothbrushes.
3Use a watering can or your hand to rinse the
frame.
4Service the frame after cleaning.
7.2.2 Cleaning the stem
1Clean stem with a cloth and soapy water.
2Service the stem after cleaning.
7.2.3 Cleaning the wheel
1Check the tyres, rims, spokes and spoke
nipples for any damage while cleaning the
wheel.
2Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
3Clean the rim with a sponge.
7.2.4 Cleaning the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
4Service the drive elements after cleaning.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairs.
This may cause a crash with injuries.
Never apply care products or oil to the brake
discs or brake linings, or the braking surfaces
on the rims.
After cleaning, servicing or repair, carry out a
few test brake applications.
Notice
Water may enter the inside of the bearings if you
use a steam jet. This dilutes the lubricant inside,
the friction increases and, as a result, the
bearings are permanently damaged in the long
term.
Never clean the pedelec with a pressure
washer.
Greased parts, such as the seat post, the
handlebars or the stem, may no longer be safely
and reliably clamped.
Never apply grease or oil to clamping sections.
Required tools and cleaning agents:
•Cloths
Sponge
•Air pump
•Brush
Toothbrush
Paintbrush
Watering can
•Bucket
•Water
Dish-washing liquid
Degreaser
Lubricant
Brake cleaner or spirit
CAUTION
!
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
WARNING
!
MY21B01 - 12_1.0_25.06.2020 73
Cleaning and servicing
7.2.5 Cleaning the chain
1Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
2Dampen a cloth with soapy water. Place the
cloth on the chain.
3Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
4If the chain is still dirty afterwards, clean with
lubricant.
5Service the chain after cleaning.
7.2.6 Cleaning the battery
Clean the battery electrical connections with a
dry cloth or paintbrush only.
Wipe off the decorative sides with a damp
cloth.
7.2.7 Cleaning the display
Carefully clean the display with a soft, damp
cloth.
7.2.8 Cleaning the motor
Carefully clean the motor with a soft, damp
cloth.
Notice
Never use aggressive (acid-based) cleaners,
rust removers or degreasers when cleaning
the chain.
Never use chain cleaning devices or chain
cleaning baths.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never clean the battery with a pressure
washer, water jet or compressed air.
Keep contacts dry and clean.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the pedelec before
cleaning.
Notice
Never clean the battery with solvents, such as
oil, thinners, alcohol or corrosion protection, or
with cleaning agents.
CAUTION
!
Notice
If water enters into the display screen, it will be
permanently damaged.
Never immerse the display in water.
Never clean with a pressure washer, water jet
or compressed air.
Never use cleaning agents.
Remove the display from the pedelec before
cleaning.
Burns from hot motor
The motor cooler can become extremely hot
during use. Touching it may cause burns.
Leave the motor to cool before cleaning.
Notice
If water penetrates the motor, it will be
permanently damaged.
Never immerse the motor in water.
Never clean with a pressure washer, water jet
or compressed air.
Never use cleaning agents.
CAUTION
!
MY21B01 - 12_1.0_25.06.2020 75
Cleaning and servicing
7.4 Maintenance
The following maintenance measures must be
performed on a regular basis.
7.4.1 Wheel
1Check the tyres for wear.
2Check the tyre pressure.
3Check the rims for wear.
The rims of a rim brake with invisible wear
indicator are worn as soon as the wear
indicator becomes visible in the area of the rim
joint.
The rims with visible wear indicator are worn as
soon as the black, all-round groove on the pad
friction surface is no longer visible. We
recommend that you also replace the rims with
every second brake lining replacement.
4Check the tension of the spokes.
7.4.1.1 Checking the tyres
Check the tyre wear. The tyre is worn if the
anti-puncture protection or the carcass cords
are visible.
A specialist dealer will need to change the tyre
if it is worn.
7.4.1.2 Checking the rims
Check the rims for wear. The rims are worn as
soon as the black, all-round groove on the pad
friction surface becomes invisible.
Contact your specialist dealer to have the rims
replaced. We recommend that you also replace
the rims at the same time as every second
brake lining replacement.
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve
Only applies to pedelecs with this equipment
The tyre pressure cannot be
measured on the simple Dunlop
valve. The tyre pressure is
therefore measured in the filling
hose when pumping slowly with
the bicycle pump.
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
1Unscrew and remove the
valve cap.
2Connect the bicycle pump.
3Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
4Correct the tyre pressure according to
specifications in the Pedelec pass.
5If the tyre pressure is too high, unfasten the
union nut, let air out and re-tighten the union
nut.
6Remove the bicycle pump.
7Screw the valve cap tight.
8Screw the rim nut gently against the rim with
the tips of your fingers.
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before maintenance.
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
Notice
If the tyre pressure is too low in the tyre, the tyre
does not achieve its load bearing capacity. The
tyre is not stable and may come off the rim.
If the tyre pressure is too high, the tyre may burst.
Check the tyre pressure as per specifications
Adjust the tyre pressure as necessary.
CAUTION
!
WARNING
!
MY21B01 - 12_1.0_25.06.2020 76
Cleaning and servicing
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve
Only applies to pedelecs with this equipment
It is recommendable to use
a bicycle pump with a
pressure gauge. The
operating instructions for
the bicycle pump must be
adhered to.
1Unscrew and remove the
valve cap.
2Open the knurled nut
around four turns.
3Carefully apply the bicycle
pump so that the valve
insert is not bent.
4Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
5Correct the tyre pressure as per the
specifications on the tyre.
6Remove the bicycle pump.
7Tighten the knurled nut with your fingers.
8Screw the valve cap tight.
9Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve
Only applies to pedelecs with this equipment
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle
pump must be adhered to.
1Unscrew and remove the
valve cap.
2Attach the bicycle pump.
3Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
4Remove the bicycle pump.
5Screw the valve cap tight.
6Screw the rim nut (1) gently against the rim
with the tips of your fingers.
7.4.2 Brake system
The maintenance interval for the brake depends
on the weather conditions and how frequent the
bicycle is used. If the pedelec is used under
extreme conditions such as rain, dirt or high
mileage, maintenance must be performed more
frequently.
7.4.3 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
1Check that the brake linings are no less than
1.8 mm wide at any point and no less than
2.5 mm between the brake lining and
supporting plate.
2Push brake lever and hold. In doing so, check
the transport safety wear gauge can fit
between the brake lining supporting plates.
The brake linings have not reached their wear
limit. Contact your specialist dealer if any of
these components are worn.
Crash caused by brake failure
Worn brake discs and brake linings, as well as a
lack of hydraulic fluid in the brake cable, reduce
the braking power. This may cause a crash with
injuries.
Check the brake disc, brake linings and
hydraulic brake system on a regular basis.
Contact your specialist dealer if any of these
components are worn.
CAUTION
!
1
MY21B01 - 12_1.0_25.06.2020 77
Cleaning and servicing
7.4.4 Checking the pressure point
Pull brake lever and hold repeatedly several
times.
If you are unable to clearly detect the pressure
point and it changes, the brake needs to be
vented. Contact your specialist dealer.
7.4.5 Checking the brake discs for wear
Check that the brake disc measures no less
than 1.8 mm in depth at any point.
The brake discs have not reached their wear
limit yet; brake discs need to be replaced if
they have. Contact your specialist dealer.
7.4.6 Checking electrical cables and
brake cables
Check all visible electrical cables and Bowden
cables for damage. If the sheathing is
compressed, a brake is defective or a light
does not work, the pedelec must be removed
from service until the lines or cables have been
repaired. Contact your specialist dealer.
7.4.7 Checking the gear shift
Check the gear shift and the shifter or the gear
twist grip setting and adjust as necessary.
7.4.8 Checking the stem
The stem and quick release system must be
inspected at regular intervals. The specialist
dealer should adjust them if necessary.
If the hexagon socket head screw is also
loosened, the headset backlash also needs to
be adjusted. Medium-strength thread locker,
such as Loctite blue, then needs to be applied
to the loosened screws and the screws
tightened as per specifications.
Contact your specialist dealer if there is any
wear or signs of corrosion.
7.4.9 Checking the USB port
7.4.10 Checking the chain tension
1Check the chain tension in three or four
positions, turning the crank a full revolution.
Figure 66: Checking the chain tension
2If the chain can be pushed more than 2 cm, the
chain will need to be re-tensioned by your
specialist dealer.
3If the chain can only be pushed up and down
less than 1 cm, the chain needs to be
slackened as required.
The ideal chain tension has been achieved if
the chain can be pushed a maximum of 2 cm in
the middle between the pinion and the toothed
wheel. The crank must also turn without
resistance.
4If a hub gear is fitted, the rear wheel must be
pushed backwards or forwards to tighten the
chain. Contact your specialist dealer.
5Check the handlebar grip is firmly in position.
Notice
Any moisture penetrating through the USB port
may cause a short circuit in the display.
Regularly check the position of the cover on the
USB port and adjust it as necessary.
Notice
Excessive chain tension increases wear. If the
chain tension is too low, there is a risk that the
chain will slip off the chain wheels.
Check the chain tension once a month.
2 cm
MY21B01 - 12_1.0_06.07.2020 78
Maintenance
8 Maintenance
You must have the specialist dealer perform
maintenance every six months as a minimum.
This is the only way to ensure that the pedelec
remains safe and fully functional. No matter
whether disc brakes need replacing, brakes
venting or wheels changing, many maintenance
tasks require technical expertise, special tools
and special lubricants. The pedelec may become
damaged if the stipulated maintenance intervals
and procedures are not carried out. That is why
only specialist dealers may carry out
maintenance.
The retailer will check the pedelec based on
the maintenance table in the Section 11.3.
The specialist dealer will inspect the pedelec
for any signs of material fatigue during basic
cleaning.
The specialist dealer will check the software
version of the drive system and update it. The
electrical connections are checked, cleaned
and preservative agent is applied. The
electrical cables are inspected for damage.
The specialist dealer will dismantle and clean
the entire suspension fork interior and exterior.
They will clean and lubricate the dust seals and
slide bushings, check the torques and adjust
the fork to the rider's preferred position. They
will also replace the sliding collar if the
clearance is too great (more than 1mm on the
fork bridge).
Injury due to damaged brakes
Special tools and specialist knowledge are
required to repair the brakes. Incorrect or
unauthorised assembly can damage the brakes.
This may lead to an accident with injuries.
Only specialist dealers may carry out repairs
on brakes.
Only carry out work or changes, such as
dismantling, sanding or painting, which are
permitted and described in the brake operating
instructions.
Injury to the eyes
Problems may arise if the settings are not made
properly and you may sustain serious injuries as
a result.
Always wear safety glasses during
maintenance work.
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before inspection.
Crash caused by material fatigue
If the service life of a component has expired, the
component may suddenly fail. This may cause a
crash with injuries.
Have the specialist dealer carry out basic
cleaning of the pedelec every six months,
preferably at the same time as the required
servicing work.
WARNING
!
CAUTION
!
Hazard for the environment due to toxic
substances
The brake system contains toxic and environmen-
tally harmful oils and lubricants. Such fluids will con-
taminate if they enter the sewers or groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
Notice
The motor is maintenance-free and may only be
opened by qualified specialist personnel.
Never open the motor.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 79
Maintenance
The specialist dealer will fully inspect the
interior and exterior of the rear frame damper,
overhaul the rear frame damper, replace all air
seals on air forks, overhaul the air suspension,
change the oil and replace the dust wipers.
They will pay particular attention to rim and
brake wear. The spokes are re-tightened in
accordance with the findings.
8.1 Suspension system
The correct execution of maintenance on the
suspension system not only guarantees a long
service life, but also ensures optimal
performance. Each maintenance interval shows
the maximum cycling hours for the corresponding
type of recommended maintenance. Depending
on terrain and environmental conditions, the
performance can be optimised through shorter
maintenance intervals.
8.1.1 Rear frame damper
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to maintain
and repair the rear frame damper.
The rear frame damper may become damaged if
the procedure is not followed as described. Only
specialist dealers may carry out maintenance on
rear frame damper.
RockShox rear frame damper
Service air chamber assembly every 50 hours
Service damper and spring every 200 hours
FOX rear frame damper
Complete maintenance (full interior and
exterior inspection, damper overhaul, air
spring overhaul, oil change and dust
wiper replacement)
every 125 hours
or once a year
Suntour rear frame damper
Complete shock absorber service
including damper reassembly and air seal
replacement every 100 hours
Injury due to explosion
The air chamber is pressurised. If the air system is
serviced in a rear frame damper, it can explode and
cause serious injury.
Wear safety goggles, protective gloves and
safety clothing when assembling or servicing
the vehicle.
Release the air for the air chambers. Detach
all air insert fitments.
Never service or dismantle a rear frame
damper if it has not completely rebounded.
WARNING
!
Intoxication from suspension oil
Suspension oil irritates the respiratory tract, leads to
germ cell mutations and sterility, causes
cancer and is toxic to touch.
Always wear safety goggles and nitrile gloves
when working with suspension oil.
Never perform maintenance when you are
pregnant.
Use an oil catchment tray under the section
where the rear frame damper is serviced.
Hazard for the environment due to toxic
substances
The rear frame damper contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
WARNING
!
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 80
Maintenance
8.1.2 Suspension fork
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to service
and repair suspension forks.
The suspension fork may be damaged if
procedures are not followed as described. Only
specialist dealers may carry out maintenance on
the suspension fork.
Suntour suspension fork
Maintenance 1
Functional check, fastening and wear test every 50 hours
Maintenance 2
Maintenance 1 + cleaning entire fork
interior and exterior / cleaning and
lubrication of dust seals and guides/
plastic bushings / check torques
every 100 hours
FOX suspension fork
Full maintenance (complete interior/
exterior inspection, damper overhaul,
replacement of air seals on air forks, air
suspension overhaul, oil change and dust
wiper replacement).
every 125 hours
or once a year
RockShox suspension fork
Stanchions for:
Paragon™, XC™ 28, XC 30, 30™, Judy®,
Recon™, Sektor™, 35™*, Bluto™, REBA®,
SID®, RS-1™, Revelation™, PIKE®, Lyrik™,
Yari™, BoXXer
every 50 hours
Maintenance of spring and damper unit
for:
Paragon, XC 28, XC 30,30 (2015 and earlier),
Recon (2015 and earlier), Sektor (2015 and
earlier), Bluto (2016 and earlier), Revelation
(2017 and earlier), REBA (2016 and earlier),
SID (2016 and earlier), RS-1 (2017 and earlier),
BoXXer (2018 and earlier)
every 100 hours
Maintenance of spring and damper unit
for:
30 (2016+), Judy (2018+), Recon (2016+),
Sektor (2016+), 35 (2020+)*, Revelation
(2018+), Bluto (2017+), REBA (2017+), SID
(2017+), RS-1 (2018+), PIKE (2014+), Lyrik
(2016+), Yari (2016+), BoXXer (2019+)
every 200 hours
Injury due to explosion
The air chamber is pressurised. If the air system is
serviced in a faulty suspension fork, it can explode
and cause serious injury.
Wear safety goggles, protective gloves and
safety clothing when assembling or servicing
the vehicle.
Release the air for the air chambers. Detach
all air insert fitments.
Never service or dismantle a suspension fork
if it has not completely rebounded.
Hazard for the environment due to toxic
substances
The suspension fork contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
WARNING
!
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 81
Maintenance
8.1.3 Suspension seat post
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to service
and repair suspension seat posts.
The suspension seat post may be damaged if
procedures are not followed as described. Only
specialist dealers may carry out maintenance on
the suspension seat post.
8.2 Axle with quick release
by.schulz seat post
Check all screws for correct tightening
torques for:
G1 and G2
After 250 km and
every 1,500 km
Suntour suspension seat post
Maintenance 1 every 100 hours
RockShox suspension seat post
Venting of remote control lever and/or
maintenance of lower seat post unit for:
Reverb™ A1/A2/B1, Reverb Stealth A1/A2/B1/
C1*, Reverb AXS™ A1*
every 50 hours
Venting of remote control lever and/or
maintenance of lower seat post unit for:
Reverb B1, Reverb Stealth B1/C1*, Reverb
AXS A1*
every 200 hours
Complete maintenance of seat post for:
Reverb A1/A2, Reverb Stealth A1/A2 every 200 hours
Complete maintenance of seat post for:
Reverb B1, Reverb Stealth B1 every 400 hours
Complete maintenance of seat post for:
Reverb AXS A1*, Reverb Stealth C1* every 600 hours
All other suspension seat posts
Maintenance every 100 hours
Crash caused by unfastened quick
release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Install the front wheel quick release lever on
the opposite side to the brake disc.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the frame may break. This will
cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers)
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 82
Maintenance
8.2.1 Checking the quick release
Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 67: Adjusting the quick release clamping force
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Check the quick release lever position and
clamping force.
Figure 68: Adjusting the quick release clamping force
8.3 Maintaining the stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the stem's quick
release system are firmly in position after the
first two hours of riding.
8.4 Adjusting the gear shift
If you cannot select the gears effortlessly, you will
need to adjust the setting for the shift cable
tension.
Carefully pull the adjusting sleeve away from
the shifter housing, turning it as you do so.
Check the gear shift function after each
adjustment.
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Troubleshooting, fault clearance and repair
9 Troubleshooting, fault clearance and repair
9.1 Troubleshooting and fault
clearance
The components of the drive system are checked
constantly and automatically. If an error is
detected, an error message appears on the
display. The drive may be shut off automatically,
depending on the type of error.
9.1.1 The drive system or display do not
start up
If the display and/or the drive system do not start up,
proceed as follows:
1Check whether the battery is switched on. If
not, start the battery.
Contact specialist dealer if the battery level
indicator LEDs do not light up.
2If the LEDs on the battery level indicator light
up, but the drive system does not start up,
remove the battery.
3Insert the battery.
4Start the drive system.
5If the drive system does not start up, remove
the battery.
6Clean all the contacts with a soft cloth.
7Insert the battery.
8Start the drive system.
9If the drive system does not start up, remove
the battery.
10 Fully charge the battery.
11 Insert the battery.
12 Start the drive system.
13 If the drive system does not start up, remove
the display.
14 Fasten the display.
15 Start the drive system.
16 Contact your specialist dealer if the drive
system does not start up.
9.1.2 Error message
If an error message is displayed, run through the
following actions:
1Make a note of the system message. There is
a table containing all system messages in
Section 6.3.1.
2Shut off and re-start the drive system.
3If the system message is still displayed,
remove the battery and then re-insert.
4Re-start the drive system.
5If the system message is still displayed,
contact your specialist dealer.
9.1.3 Assistance function errors
Symptom Cause Remedy
Assistance is not
available.
Is the battery charged sufficiently? 1Check battery is charged.
2Recharge the battery if it is almost flat.
Are you riding up long inclines in
summer weather or have you been
carrying a heavy load for a long time?
The battery may be too hot.
1Switch off the drive system.
2Wait a moment and then check again.
The rechargeable battery, the display
or the assistance switch may be
connected incorrectly or one or more of
them may have a problem.
Contact your specialist dealer.
Is the speed too high? Check on-screen indicators. The electronic gear assistance
only works up to a maximum speed of 25 km/h.
Assistance is not
available.
Are the pedals being pushed? The pedelec is not a motorbike. Push the pedals.
Is the assistance mode set to [OFF]?
1Set the assistance mode to a different level of assistance than
[OFF].
2Contact your specialist dealer if you still feel that the no
assistance is being supplied.
Is the system switched on? Press the battery on-off button to switch it on again.
Table 51: Level of assistance error solution
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Troubleshooting, fault clearance and repair
9.1.4 Battery error
The assisted journey
distance is too short.
The journey distance can be shorter
depending on the road conditions, the
gear level and the entire light usage
time.
1Check battery is charged.
2Recharge the battery if it is almost flat.
The battery does not perform as well in
winter weather. This does not indicate a problem.
The battery is a consumable. Repeated
charging and long periods of use cause
the battery to degrade (loss of power).
If the distance you can cover with one single charge is very
short, replace the battery with a new one.
Is the battery fully charged?
If the distance covered with a fully charged battery has
become shorter, the battery may be affected. Replace the
battery with a new one.
It is difficult to pedal.
Are the tyres pumped to an adequate
pressure?
Pump up tyres.
Is the assistance mode set to OFF?
1Set level of assistance to [BOOST].
2Contact your specialist dealer if you still feel that the no
assistance is being supplied.
The battery charge might be low.
Check how powerful assistance is again after charging the
battery. Contact your specialist dealer if you still feel that the
pedelec does not provide assistance.
Have you switched on the system with
your foot on the pedal?
1Switch the system on again without applying pressure to the
pedal. Contact your specialist dealer if you still feel that the
pedelec does not supply assistance.
Symptom Cause Remedy
Table 51: Level of assistance error solution
Symptom Cause Remedy
The battery discharges
quickly. The battery may be at the end of its
useful life.
Replace the battery with a new one.
The battery cannot be
recharged.
Is the charger mains plug firmly
connected to the socket?
1Pull out the charger mains plug and reconnect it again.
2Try charging again.
3If the battery still won't recharge, contact your specialist
dealer.
Is the charger plug firmly connected to
battery?
1Pull out the charger mains plug and reconnect it again.
2Try charging again.
3If the battery still won't recharge, contact your specialist
dealer.
Is the adapter firmly connected to the
charger plug or the battery's charging
port?
1Connect the adapter firmly to the charger plug or the battery's
charging port.
2Re-start the charging process.
3Contact your specialist dealer if the battery still does not
charge.
Is the battery, the connection terminal
for the battery charger, charger adapter
or battery dirty?
1Wipe the connection terminal with a dry cloth to clean it.
2Try charging again.
3If the battery still won't recharge, contact your specialist
dealer.
Table 52: Error solution for battery
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Troubleshooting, fault clearance and repair
9.1.5 Display errors
The battery does not start
charging when the
charger is connected.
The battery may be at the end of its
useful life.
Replace the battery with a new one.
The battery and charger
become hot.
The temperature of the battery or the
charger may have exceeded the
operating temperature range.
1Stop the charging process.
2Wait a while and then start charging again.
3If the battery is too hot to touch, there might be a problem with
the battery. Contact your specialist dealer.
The charger is hot. If the charger is used continuously to
charge batteries, it may become hot.
Wait a while before using the charger again.
The LED on the charger
does not light up.
Is the charger plug firmly connected to
battery?
1Check the connection to the external body before inserting the
charger plug again.
2If nothing changes, contact your specialist dealer.
Is the battery fully charged?
The LED on the battery charger will go out when the battery is fully
charged. This is not a malfunction.
1Pull out the charger mains plug and reconnect it again.
2Then try charging again.
3If the LED on the charger still does not light up, contact your
specialist dealer.
The battery cannot be
removed.
Contact your specialist dealer.
The battery cannot be
inserted.
Contact your specialist dealer.
Fluid is leaking from the
battery.
Observe all the safety instructions in Section 2 Safety.
There is an unusual smell.
1Move away from the battery immediately.
2Contact the fire service immediately.
3Observe all the safety instructions in Section 2 Safety.
Fumes are emitted from
the battery. 1Move away from the battery immediately.
2Contact the fire service immediately.
3Observe all the safety instructions in Section 2 Safety.
Symptom Cause Remedy
Table 52: Error solution for battery
Symptom Cause Remedy
No data are shown on the
monitor if you press the
on-off button on the
battery.
The battery charge level may be
insufficient.
1Charge the battery.
2Switch the power on.
Is the power switched on? Keep the battery on-off button pressed down to switch on the
power again.
Is the battery charged? If the battery is fitted to the pedelec and is being charged, it
cannot be switched on. Stop the charging process.
Is the connector fitted to the power
cable correctly?
Check that the power cable connector has not been
disconnected. If you are not sure, contact your specialist
dealer.
A component may be connected which
the system is unable to recognise.
Contact your specialist dealer.
Table 53: Display error solution
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Troubleshooting, fault clearance and repair
9.1.6 Lighting does not work
9.1.7 Other errors
The gear level is not
shown on the display
screen.
The gear level is only shown if the
electronic gear shift is used.
Check whether the power cable pug has been disconnected. If
you are not sure, contact your specialist dealer.
The settings menu cannot
be opened while you are
riding.
The product is designed in such a way
that the settings menu cannot be
opened if the system detects that
someone is riding the pedelec. This is
not a malfunction.
Stop the pedelec and then adjust the settings.
The time display is
flashing "0:00". The coin cell in the display has come to
the end of its service life.
Replace the coin cell in the display.
Symptom Cause Remedy
Table 53: Display error solution
Symptom Cause Remedy
The front light or rear light
does not go on, even
when the switch is
pressed.
The basic settings in the electric drive
system have probably been configured
incorrectly. The light is defective.
1Take the pedelec out of service immediately.
2Contact your specialist dealer.
Table 54: Error solution for battery
Symptom Cause Remedy
Two beeps will sound if a
switch is pressed but the
switch cannot be
operated.
Pressed switch mode has been
deactivated.
This is not a malfunction.
Three beeps are
sounded. A fault or warning has occurred.
This occurs when a warning or an error is shown on the
display screen. Follow the instructions for the code indicated
on screen in Section 6.2 System Messages.
When you use an
electronic gear shift, you
can feel that pedal
assistance becomes
weaker when the gear is
changed.
This is because the computer sets the
pedal assistance to the optimum level.
This is not a malfunction.
A noise can be heard
after switching.
Contact your specialist dealer.
It is normal to hear a
noise coming from the
rear wheel when cycling
as normal.
The gear shift setting may not have
been made properly.
Contact your specialist dealer.
If you stop the pedelec,
gear transmission does
not switch to the position
pre-configured in the
functional feature.
You may have applied too much
pressure onto the pedals.
It is easier to change gears if you press onto the pedals gently.
Table 55: Error solution for battery
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Troubleshooting, fault clearance and repair
9.2 Repair
Special knowledge and tools are required for
many repairs. That is why only a specialist dealer
may perform repairs such as:
Replacing tyres and rims
Replacing rims and brake linings or brake discs
Replacing and tensioning the chain.
9.2.1 Original parts and lubricants
The individual pedelec parts have been carefully
selected and matched to one other.
Only original parts and lubricants must be used for
maintenance and repair.
The constantly updated accessory approval and
parts lists are in Section 11 Documents and
Drawings.
Observe the operating instructions for the new
components.
9.2.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.2.3 Adjusting the headlight
The headlight must be set, so that its light beam
shines on the road 10 m in front of the pedelec.
9.2.4 Tyre clearance check
The tyre needs to be checked each time a
suspension fork tyre is changed to another size.
1Release pressure from the fork.
2Press fork together fully.
3Measure the gap between the top of the tyre
and the crown's lower surface. The gap must
not be less than 10 mm. If the tyre is too large,
the tyre will touch the crown's lower surface if
the fork is fully pressed together.
4Release pressure on fork and pump it up again
if it is an air suspension fork.
5Take into account the fact that the gap will be
smaller if there is a guard. Check again to
ensure that there is sufficient clearance for the
tyre.
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Recycling and disposal
10 Recycling and disposal
This device is marked according to the
European Directive 2012/19/EU on
waste electrical and electronic
equipment – WEEE and the European
Directive 2006/66/EC on accumulators.
The directive provides the framework for
the return and recycling of used devices
across the EU. As a consumer, you are legally
required to return all used batteries of any type. It
is forbidden to dispose of batteries in domestic
waste. The manufacturer is obliged to take back
used and old batteries free of charge as per
Section 9 German Batteries Act. You thus meet
statutory obligations and help to protect the
environment. The pedelec, battery, motor, display
screen and charger are recyclable materials. You
must dispose of and recycle them separately from
the domestic waste in compliance with applicable
statutory regulations. Separate collection and
recycling saves reserves of raw materials and
ensures that all the regulations for protection of
health and the environment are adhered to when
recycling the product and/or the battery.
Never dismantle the pedelec, batteries or
charger for disposal.
The pedelec, display screen, the unopened
and undamaged battery and the charger can
be returned to any specialist dealer free of
charge. Depending on the region, further
disposal options may be available.
Store the individual parts of the
decommissioned pedelec in a dry place, free
from frost, where they are protected from direct
sunlight.
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Documents
11 Documents
11.1 Parts list
11.1.1 Bulls Cross Mover Evo 1
21-17-1016 Gent, 21-17-1017 Trapez and 21-17-1018 Wave
Component Manufacturer Model Details
Handlebars HB-RB11
HB-411 (wave) 25, 4 mm
Stem AL-822
Fork Suntour NEX-E25 DS CTS 63 mm
Pedal Wellgo C-157
Crank FSA 175 mm
Saddle SR Essenza PLUS Moderate/Relaxed
Seat post SP-F102 10 mm offset, 30.9 x 350 mm,
Handles VLG-1115AD2 134.5 / 92 mm
Brake Tektro HD-T275 (front and rear) Hydraulic disc brake
Brake lever n.a.
Brake disc 180 mm (front), 180 mm (rear) diameter
Rims DDM-2
Hub, front FORMULA DC-20FQR 6-BOLT TYPE, 14Gx36H
Hub, rear FORMULA DC-22RQR 6-BOLT TYPE, 13Gx36H,
Tyres Supero Optima Safe 50-622 50-622
Pannier rack SW-KM038S SW-KM038S
Mudguard SKS PET A60 S Shiny
Motor BOSCH Performance Line CX BDU450CX
Rechargeable battery BOSCH PowerTube 500 W
Display BOSCH Intuvia 1270.020.909
Charger BOSCH Standard charger 2 A
Headlight Fuxon FS-50 50 LUX
Rear lamp R-232EB
Shifter Shimano Altus, 8-gear
Chainring 11-34T
Kickstand SW-RA031J
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Documents
11.1.2 Bulls Cross Mover Evo 2
21-17-1013 Gent, 21-17-1014 Trapez and 21-17-1015 Wave
Component Manufacturer Model Details
Handlebars HB-RB12
HB-SM7 (wave) 31, 8 mm
Stem AS-ZGD2
Fork Suntour NEX-E25 DS HLO CTS 63 mm
Pedal Wellgo C-157
Crank FSA 175 mm
Saddle Comodoro
Seat post SP-F102 10 mm offset, 30.9 x 350 mm,
Handles VLG-1115AD2 134.5 / 92 mm
Brake Shimano BR-MT200 (front and rear) Hydraulic disc brake
Brake lever Shimano BL-MT201 (front and rear) n.a.
Brake disc 180 mm (front) 160 mm (rear)
Rims Taurus 2000
Hub, front Shimano HB-M600QR
Hub, rear Shimano FH-M6000QR
Tyres Schwalbe Marathon Plus 50-622
Pannier rack Standwell SW-KM038S SW-KM038S
Mudguard SKS PET A60 S Matt
Motor BOSCH Performance Line CX BDU450CX
Rechargeable battery BOSCH PowerTube 625 W
Display BOSCH Intuvia 1270.020.909
Charger BOSCH Standard charger 2 A
Headlight Fuxon FS-70 70 LUX
Rear lamp R-232EB
Shifter Shimano Deore, 10-gear
Chainring Shimano CS-M4100 11-36T
Kickstand Pletscher Comp. 40 Flex
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Documents
11.2 Assembly report
Date: Frame number:
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance Rejection
Front wheel Assembly O.K. Loose Adjust quick release
Kickstand Check mount fastening Functional check O.K. Loose Retighten screws
Tyres Tyre pressure check O.K. Tyre pressure too low/too
high Adjust tyre pressure
Frame Check for damage –
fracture, scratches O.K. Damage detected Take out of operation, new frame
Handles, coverings Check mount fastening O.K. Not provided Retighten screws, new handles or
coverings as specified in parts list
Handlebars, stem Check mount fastening O.K. Loose Retighten screws; new stem as
specified in parts list if necessary
Steering headset Check for damage Functional check O.K. Loose Retighten screws
Saddle Check mount fastening O.K. Loose Retighten screws
Seat post Check mount fastening O.K. Loose Retighten screws
Protective plate Check mount fastening O.K. Loose Retighten screws
Pannier rack Check mount fastening O.K. Loose Retighten screws
Attachments Check mount fastening O.K. Loose Retighten screws
Bell Functional check O.K. No ring, too quiet, missing New bell as specified in the parts
list
Suspension elements
Fork, suspension
fork Check for damage O.K. Damage detected New fork as specified in the parts
list
Rear frame damper Check for damage O.K. Damage detected New fork as specified in the parts
list
Suspension seat post Check for damage O.K. Damage detected New fork as specified in the parts
list
Brake system
Brake lever Check mount fastening O.K. Loose Retighten screws
Brake fluid Check fluid level O.K. Too little Refill with brake fluid; new brake
hoses if damaged
Brake linings
Check brake linings,
brake discs or rims for
damage O.K. Damage detected New brake linings, brake discs or
rims
Back-pedal brake
braking armature Check mount fastening O.K. Loose Retighten screws
Light system
Rechargeable battery First examination O.K. Error message Take out of service; contact
battery manufacturer, new battery
Light cabling Connections, correct
wiring O.K. Cable defective, no light New cabling
Rear light Side light Functional check O.K. No constant light Take out of service; new rear
light as specified in parts list;
replace if necessary
Front light Side light, daytime riding
light Functional check O.K. No constant light Take out of service; new front
light as specified in parts list;
replace if necessary
Reflectors All complete, state,
fastening O.K. Damaged or not all
complete New reflectors
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Documents
Technical inspection, checking safety, test ride
Drive/gear shift
Chain/cassette/
pinion/chainring Check for damage O.K. Damage Refasten if necessary or replace
as specified in parts list
Chain guard/spoke
guard Check for damage O.K. Damage Replace as specified in parts list
Bottom bracket axle/
crank Check mount fastening O.K. Loose Retighten screws
Pedals Check mount fastening O.K. Loose Retighten screws
Shifter Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables Check for damage Functional check O.K. Loose or defective Adjust shift cables; new shift
cables if necessary
Front derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Rear derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Electric drive
Display Check for damage Functional check O.K. No screen, defective
screen display
Restart, test battery, new
software, or new display – take
out of service,
Electric drive control
panel DriveCheck for damage Functional check O.K. No response Restart; contact control panel
manufacturer, new control panel
Tachometer Speed measurement O.K. Pedelec travelling 10% too
fast/slow Take pedelec out of service until
the source of the error is found
Cabling Visual inspection O.K. Failure in system, damage,
kinked cables New cabling
Battery mount Firmly in position, lock,
contacts Functional check O.K. Loose; lock doesn't close,
no contacts New battery mount
Motor Visual inspection and
mount O.K. Damage, loose Refasten motor, contact motor
manufacturer, new motor
Software Check version In latest
version Not latest version Import update
Components Description Criteria Measures if rejected
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long Locate defective part in brake
system and correct
Gear shift under
operating load
Functional check O.K. Problems when shifting
gear Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
Functional check O.K. Suspension too deep or no
longer exists Locate defective component and
correct
Electric drive
Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system Functional check O.K. No continuous light, too
bright Locate defective part in light
system and correct
Test ride No strange
noises Strange noises Locate source of noise and
correct
Date
Fitter's name:
Final inspection by workshop manager
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Documents
11.3 Maintenance instructions
Diagnosis and documentation of current status
Date: Frame number:
Components Frequency Description Criteria Measures if rejected
Inspection Tests Maintenance Accept-
ance
Rejection
Front wheel 6 months Assembly O.K. Loose Adjust quick release
Kickstand 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Tyres 6 months Tyre pressure check O.K. Tyre pressure
too low/too high Adjust tyre pressure
Frame 6 months Check for damage –
fracture, scratches O.K. Damage
detected Take pedelec out of service,
new frame
Handles,
coverings 6 months Wear; check if
fastened securely O.K. Not provided Retighten screws, new
handles or coverings as
specified in parts list
Handlebars,
stem 6 months Check mount fastening O.K. Loose Retighten screws; new stem
as specified in parts list if
necessary
Steering
headset 6 months Check for damage Functional check Lubricating and
adjustment O.K. Loose Retighten screws
Saddle 6 months Check mount fastening O.K. Loose Retighten screws
Seat post 6 months Check mount fastening O.K. Loose Retighten screws
Protective plate 6 months Check mount fastening O.K. Loose Retighten screws
Pannier rack 6 months Check mount fastening O.K. Loose Retighten screws
Attachments 6 months Check mount fastening O.K. Loose Retighten screws
Bell 6 months Functional check O.K. No ring, too
quiet, missing New bell as specified in the
parts list
Suspension elements
Fork,
suspension fork
To manu-
facturer's
specifica-
tions*
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected New fork as specified in the
parts list
Rear frame
damper
To manu-
facturer's
specifica-
tions*
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected New fork as specified in the
parts list
Suspension
seat post
To manu-
facturer's
specifica-
tions*
Check for damage Maintenance as
specified by
manufacturer O.K. Damage
detected New fork as specified in the
parts list
Brake system
Brake lever 6 months Check mount fastening O.K. Loose Retighten screws
Brake fluid 6 months Check fluid level Depending on time of
year O.K. Too little Top up brake fluid; take
Pedelec out of service if
damaged; new brake hoses
Brake linings 6 months Check brake linings,
brake discs or rims for
damage O.K. Damage
detected New brake linings, brake
discs or rims
Back-pedal
brake braking
armature
6 months Check mount fastening O.K. Loose Retighten screws
Brake system 6 months Check mount fastening Functional check O.K. Loose Retighten screws
* see Section 8.1
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Documents
Inspection Tests Maintenance Accept-
ance
Rejection
Light system
Rechargeable
battery 6 months First examination O.K. Error message Contact battery
manufacturer; take out of
service, new battery
Light cabling 6 months Connections, correct
wiring O.K. Cable defective,
no light New cabling
Rear light 6 months Side light Functional check O.K. No constant light New rear light as specified in
parts list; replace if
necessary
Front light 6 months Side light, daytime
riding light Functional check O.K. No constant light New front light as specified
in parts list; replace if
necessary
Reflectors 6 months All complete, state,
fastening O.K. Damaged or not
all complete New reflectors
Drive/gear shift
Chain/cassette/
pinion/
chainring
6 months Check for damage O.K. Damage Refasten if necessary or
replace as specified in parts
list
Chain guard/
spoke guard 6 months Check for damage O.K. Damage Replace as specified in parts
list
Bottom bracket
axle/crank 6 months Check mount fastening O.K. Loose Retighten screws
Pedals 6 months Check mount fastening O.K. Loose Retighten screws
Shifter 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables 6 months Check for damage Functional check O.K. Loose or
defective Adjust shift cables; new shift
cables if necessary
Front derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible Adjust
Rear derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible Adjust
Electric drive
Display 6 months Check for damage Functional check O.K. No screen,
defective screen
display
Restart, test battery, new
software, or new display –
take out of service,
Electric drive
control panel 6 months DriveCheck for
damage Functional check O.K. No response Restart; contact control
panel manufacturer, new
control panel
Tachometer 6 months Speed measurement O.K. Pedelec
travelling 10%
too fast/slow
Take pedelec out of service
until the source of the error is
found
Cabling 6 months Visual inspection O.K. Failure in
system, damage,
kinked cables
New cabling
Battery mount 6 months Firmly in position, lock,
contacts Functional check O.K. Loose; lock
doesn't close, no
contacts
New battery mount
Motor 6 months Visual inspection and
mount O.K. Damage, loose Refasten motor, contact
motor manufacturer, new
motor; take out of service
Software 6 months Check version In latest
version Not latest version Import update
Components Frequency Description Criteria Measures if rejected
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Technical inspection, checking safety, test ride
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system 6 months Functional check O.K. No full braking; braking
distance too long Locate defective part in brake
system and correct
Gear shift under
operating load 6 months Functional check O.K. Problems when shifting
gear Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
6 months Functional check O.K. Suspension too deep or no
longer exists Locate defective component and
correct
Electric drive 6 months Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system 6 months Functional check O.K. No continuous light, too
bright Locate defective part in light
system and correct
Test ride 6 months Functional check No strange
noises Strange noises Locate source of noise and
correct
Date
Fitter's name:
Final inspection by workshop
manager
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11.4 Charger operating instructions
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MY21B01 - 12_1.0_25.06.2020 98
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D
eBike Battery Charger 36-6/230
0 275 007 918
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 2.15A
Output: 36V 6A
Made in Vietnam
Fast Charger BCS250
eBike Battery Charger 36-4/230
0 275 007 907
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 1.5A
Output: 36V 4A
Made in PRC
Robert Bosch GmbH
72757 Reutlingen
Germany
Standard Charger BCS220
Robert Bosch GmbH
72757 Reutlingen
Germany
Standard Charger
Fast Charger
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MY21B01 - 12_1.0_25.06.2020 103
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C,GGNNBG$NGG
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*!PNG$NG
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 !!CC" !"" 0"
"$$#NGM$G
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NG
"$$ "
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G!GGPKHNGG
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
#N*GNGG!MG
G!$!
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
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OGG,GGL!M
GG!$!G
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OGGL!!MGL
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GNG!!GG!L
%*&G!GGL!L

GPKHGG!%*&NG!G
GKG!!PKHL
EBEDF AGA*C
MY21B01 - 12_1.0_25.06.2020 104
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KGI'
Q]iNGGGNGPKH
!GQ]iG
GA*NG!MGPKHL
!!GL!,G!NNG
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!!NG!GNNL
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HGGNG!GN
GG
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,G!NN
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MG!,
#NGG!!NGN
GMNN,GGG,,GN*
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MY21B01 - 12_1.0_06.07.2020 105
Glossary
12 Glossary
Brake lever
Source: EN 15194:2017: lever used to apply the
brake.
Braking distance
Source: EN 15194:2017: distance travelled by a
pedelec between the commencement of braking
and the point at which the pedelec comes to rest.
Cargo bike
Source: DIN 79010: bicycle mainly designed to
carry goods.
CE marking
Source: Directive 2006/42/EC on Machinery: the
manufacturer uses the CE marking to declare that
the Pedelec complies with the applicable
requirements.
City and trekking bicycles
Source: EN-ISO 4210 - 2: pedelec designed for
use on public roads primarily for means of
transportation or leisure.
Consumables
Source: EN 82079-1: any part or material that is
necessary for continued use or maintenance of
the product.
Decommissioning
Source: DIN 31051: intentional, unlimited
interruption in an object's functional capability.
Disc brake
Source: EN 15194:2017: brake in which brake
pads are used to grip the lateral faces of a thin
disc attached to or incorporated in the wheel hub.
Drive belt
Source: EN 15194:2017: seamless ring belt which
is used as a means of transmitting motive force.
Electrical control system
Source: EN 15194:2017: electronic and/or
electrical component, or an assembly of
components provided for installation into a
vehicle, together with all electrical connections
and associated wiring for the motor electrical
power assistance.
Electrically power assisted cycle, pedelec
Source: EN 15194:2017: electrically power
assisted cycle, equipped with pedals and an
auxiliary electric motor, which cannot be propelled
exclusively by means of the auxiliary electric
motor, except in start-up assistance mode.
Fault
Source: EN 13306:2018-02, 6.1: state of an item
(4.2.1) characterized by inability to perform a
required function (4.5.1), excluding the inability
during preventive maintenance or other planned
actions, or due to lack of external resources.
Folding bicycle
Source: EN-ISO 4210-2: bicycle designed to fold
into a compact form, facilitating transport and
storage.
Fork steerer
Source: EN 15194:2017: part of a fork that rotates
about the steering axis of a bicycle frame head
tube. It is normally connected to the fork crown or
directly to the fork legs, and is normally the point
of connection between the fork and the handlebar
stem.
Fracture
Source: EN 15194:2017: unintentional separation
into two or more parts.
Instruction handbook
Source: ISO/FDIS 20607:2018: part of the user
information that machine manufacturers provide
to machine operators; it contains guidance,
instructions and tips related to the use of the
machine in all its life cycle phases.
Maintenance
Source: DIN 31051: maintenance is generally
performed at regular intervals and often carried
out by trained technical staff. This ensures a
maximum service life and low wear and tear for
the maintained items. Proper maintenance is
often also a pre-requisite for providing a warranty.
Maximum continuous power
Source: ZEG: the maximum continuous power is
the maximum power for the electric motor output
shaft during 30 minutes.
MY21B01 - 12_1.0_06.07.2020 106
Glossary
Maximum saddle height
Source: EN 15194:2017: vertical distance from
the ground to the point where the top of the seat
surface is intersected by the seat-post axis,
measured with the saddle in a horizontal position
and with the seat-post set to the minimum
insertion-depth mark.
Maximum tyre pressure
Source: EN 15194:2017: maximum tyre pressure
recommended by the tyre or rim manufacturer for
a safe and efficient performance. If the rim and
tyre both indicate a maximum tyre pressure, the
maximum inflation pressure is the lower of the two
pressures indicated.
Minimum insertion depth mark
Source: EN 15194:2017: mark indicating the
minimum insertion-depth of handlebar stem into
fork steerer (fork stem) or seat post into frame.
Model year
Source: ZEG: the model year refers to the first
production year that the series-manufactured
pedelec was manufactured in the version in
question and is not always identical with the year
of manufacture. The year of manufacture may be
before the model year in some cases. If no
technical modifications are introduced to the
series, production may continue of pedelecs from
a previous model year.
Mountain bike
Source: EN-ISO 4210-2: bicycle designed for use
off-road on rough terrain, on public roads, and on
public pathways, equipped with a suitably
strengthened frame and other components, and,
typically, with wide-section tyres with coarse tread
patterns and a wide range of transmission gears.
Off-road rough terrain
Source: EN 15194:2017: coarse pebble tracks,
forest trails, and other general off-road tracks
where tree roots and rocks are likely to be
encountered.
Permitted total weight
Source: EN 15194:2017: weight of the fully
assembled pedelec plus the rider and baggage,
as specified by the manufacturer.
Quick-release device, quick release
Source: EN 15194:2017: lever actuated
mechanism that connects, retains or secures a
wheel or any other component.
Racing bicycle
Source: EN-ISO 4210-2: bicycle intended for high-
speed amateur use on public roads having a
steering assembly with multiple grip positions
allowing for an aerodynamic posture, a multi-
speed transmission system, tyre width not greater
than 28 mm and a maximum mass of 12 kg for the
fully assembled bicycle.
Seat post
Source: EN 15194:2017: component that clamps
the saddle (with a bolt or assembly) and connects
it with the frame.
Shut-off speed
Source: EN 15194:2017: speed reached, by the
pedelec, at the moment the current has dropped
to zero or to the no load current value.
Spare part
Source: EN 13306:2018-02, 3.5: item intended to
replace a corresponding item in order to retain or
maintain the original required function of the item.
Suspension fork
Source: EN 15194:2017: front fork incorporating
controlled, axial flexibility to reduce the
transmission of road-shocks to the rider.
Suspension frame
Source: EN 15194:2017: frame incorporating
controlled, vertical flexibility to reduce the
transmission of road-shocks to the rider.
Type number
Source: ZEG: all pedelec models have an eight-
digit type number which is used to specify the
design model year, the type of pedelec and the
version.
Wear
Source: DIN 31051: reduction in useful life (4.3.4),
caused by chemical and/or physical processes.
MY21B01 - 12_1.0_06.07.2020 107
Glossary
Weight of ready-to-ride bicycle
Source: ZEG: the indicated weight for a ready-to-
ride bicycle refers to the weight of a pedelec at the
time of sale. The weight of each additional
accessory must be added to this weight.
Wheel
Source: EN 15194:2017: assembly or
combination of hub, spokes or disc, and rim, but
excluding tyre assembly.
Work environment
Source: EN ISO 9000:2015: set of conditions
under which work is performed.
Year of manufacture
Source: ZEG: the year of manufacture is the year
in which the Pedelec was manufactured. The
production period is always from August to July of
the following year.
Young adult bicycle
Source: EN-ISO 4210-2: bicycle designed for use
on public roads by a young adult whose weight is
less than 40 kg, with maximum saddle height of
635 mm or more and less than 750 mm. (see
ISO 4210).
12.1 Abbreviations
ABS anti-blocking system
ECP electronic cell protection
12.2 Simplified terms
The following terms are used for better legibility:
Term Meaning
Operating
instructions
Original operating
instructions
Motor Drive motor, sub-system
Table 56: Simplified terms
MY21B01 - 12_1.0_06.07.2020 108
Appendix
Appendix
I Translation of the original EC/EU Declaration of Conformity
The machine, pedelec types:
21-15-1016 BULLS Cross Mover Evo 1, Trapez City and trekking bicycle
21-15-1018 BULLS Cross Mover Evo 1, Wave City and trekking bicycle
21-15-1027 BULLS Cross Rider Evo 1 (München), Gent City and trekking bicycle
21-15-1028 BULLS Cross Rider Evo 1 (München), Trapez City and trekking bicycle
21-15-1069 BULLS Cross Street E1, Gent City and trekking bicycle
21-15-1070 BULLS Cross Street E1, Trapez City and trekking bicycle
21-17-1013 BULLS Cross Mover Evo 2, Gent City and trekking bicycle
21-17-1014 BULLS Cross Mover Evo 2, Trapez City and trekking bicycle
21-17-1015 BULLS Cross Mover Evo 2, Wave City and trekking bicycle
21-17-1029 BULLS Cross Rider Evo 2 (Cologne), Gent City and trekking bicycle
21-17-1030 BULLS Cross Rider Evo 2 (Cologne), Trapez City and trekking bicycle
21-17-1045 BULLS Cross Rider Evo 2 (Cologne), Wave City and trekking bicycle
21-17-1064 BULLS Cross Mover Evo 2, 26'', Wave City and trekking bicycle
Year of manufacture 2020 and year of manufacture 2021, complies with the following applicable EU provisions:
Machinery Directive 2006/42/EC
Directive 2011/65/EU RoHS
Electromagnetic Compatibility Directive 2014/30/EU.
The safety objectives in the Low Voltage Directive 2014/35/EU have been met in compliance with Appendix
I, No. 1.5.1 of the Machinery Directive 2006/42/EC.
The following harmonised standards have been applied:
ISO 20607:2018 Safety machinery – Instruction handbook – General drafting principles
EN 15194:2017 Cycles – Electrically power assisted cycles – EPAC Bicycles
The following other technical standards have been applied:
EN 11243:2016: Cycles – Luggage carriers for bicycles – Requirements and test
methods
Cologne, 02/06/2020
…………………………………………………………………………………………………………………
Egbert Hageböck, Chairman, ZEG Zweirad-Einkaufs-Genossenschaft eG
* Community member who is authorised to compile the technical documentation
Manufacturer
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Authorised representative for documentation*
Janine Otto
c/o ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
MY21B01 - 12_1.0_25.06.2020 109
Appendix
II Declaration of conformity for incomplete machine
MY21B01 - 12_1.0_25.06.2020 110
Appendix
MY21B01 - 12_1.0_25.06.2020 111
Appendix
MY21B01 - 12_1.0_25.06.2020 112
Keyword index
14 Keyword index
A
Alternative equipment, 107
Articulated shaft,
- care 74
B
Basic cleaning 72
Battery housing, 18, 19
Battery key, 18
Battery level indicator
(battery), 18, 19, 31
Battery level indicator (display
screen), 32
Battery lock, 18, 19
Battery,
-charging, 61
-checking, 38
- cleaning, 73
- disposing of, 89
- inserting, 59
-removing, 59, 60
- waking, 62
Bell, 31
Belt tension, 77
Brake calliper, 16
Brake disc, 16
-check 77
Brake lever, 31
Brake lining, 16
-check 76
- maintaining, 76
Brake,
-check brake cables 77
-check brake disc 77
- check brake linings 76
- check pressure point 77
Break in operation, 37
-carrying out, 37
- preparing, 37
Button,
On-Off (battery) 19
Buttons, 31
C
Cassette,
- care 74
Chain drive, 17
Chain guard,
- checking, 57
Chain tension, 77
Chain wheel, 17
Chain wheels,
- care 74
Chain, 14, 17
- care, 74
-maintaining, 77
Charger,
- disposing of, 89
Charging port cover, 18, 19
Charging port, 18, 19
Clamping force,
-Checking the quick
releases, 41
- Setting the quick
releases, 41
Control panel 20, 31
D
Direction of travel, 17
Display battery, 20
Display, 17, 20
- attaching, 64
- charging the battery, 64
-cleaning, 73
- removing, 64
Position, 31
Drive system, 17
- switching off, 63
-switching on, 63
E
Electric gear shift 17
Electrical cable,
- check 77
Emergency stop system 12
F
Fork,
- care, 74
- setting the compression
damper, 69
Frame battery, 17
-inserting, 59
- removing, 59
Frame, 14
- care, 74
-cleaning, 72
Front derailleur,
- care, 74
Front wheel brake, 16
- braking, 68
Front wheel, see Wheel
Function display, 32
G
Gear recommendation, 32, 33
Gear shift twist grip, 31, 32
- checking, 77
Gear shift,
- maintaining, 77
- switching, 70
Gears,
- check 77
H
Handlebars, 14, 31
- check 45
Headlight, 17, 31
Hub, 15
I
indicator 32
Info button (control panel), 31
Info button (display), 31
Initial commissioning, 40
Integrated battery, 17
- removing, 60
J
Jockey wheel,
- care 74
Journey information, 33
-resetting, 66
- switching, 66
Avg. speed, 33
Clock, 33
Maximum, 33
Odometer, 33
Range, 33
Trip distance, 33
Trip Time, 33
EN_1.0_BULLS BOSCH Intuvia MY21.book Page 112 Thursday, July 9, 2020 12:55 PM
Keyword index
MY21B01 - 12_1.0_25.06.2020
113
L
Level of assistance, 31, 32
- selecting, 66
ECO, 32
SPORT, 32
TOUR, 32
TURBO, 32
M
Minimum insertion depth
marking, 52
Minus button, 31
Model year, 8
Motor power used, 32
Motor, 17
- cleaning, 73
Mudguards,
- checking, 57
O
On-Off button (battery), 18,
19, 31
On-Off button (display), 31
On-screen indicator, 32, 56
Operating status indicator, 31
P
Pannier rack battery, 17
- removing, 59
Pannier rack, 14
- changing, 58
- checking, 57
- using, 58
Pedal, 17
- care, 74
- cleaning, 71
Plus button, 31
Position, 31
Protective cap 31
Push assist button, 31
Push assist,
- using, 65
R
Rear light, 17
Rear wheel brake, 16
RESET button, 31
Retainer guard, 19
Riding light button, 31
Riding light, 20, 32
- checking function, 57
Rim, 15
- check 75
- checking, 75
S
Saddle, 14
- changing the saddle tilt,
51
- changing the seat length,
52
- determining the saddle
height, 51, 52
Seat post, 14
Securing hook, 19
Shifter, 31
- checking, 77
- setting, 82
Spoke, 15
Stem,
- care, 74
- check 45, 77
- cleaning, 72
Suspension fork,
- cleaning, 71
System message, 35, 48
System setting, 34
changeable, 33, 34, 35,
66
System data, 34
T
Tachometer, 32
Total journey duration, 34
Transportation, 36
Transporting, see
Transportation
Type number, 8
Tyres, 15
- check 75
- check tyre pressure 75
- checking, 75
U
USB port, 31
- check 77
- using, 65
V
Valve, 15
Dunlop valve, 15
Presta valve, 15
Schrader valve, 15
W
Weight,
permitted total weight, 8
Wheel,
- cleaning, 72
- installing 40, 41, 43, 44,
45
- maintaining, 75
Winter break, see Break in
operation
EN_1.0_BULLS BOSCH Intuvia MY21.book Page 113 Thursday, July 9, 2020 12:55 PM
50


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