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Pegasus SHIMANO SYSTEM 6100 DISPLAY Manual

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TRANSLATION OF THE ORIGINAL OPERATING
INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
MY20P03-22_1.0_18.07.2019
Shimano 6100 operating instructions
Opero Evo 5R Di2, Opero Evo 5F Di2 Automatic Belt, Opero Evo 5F Di2 NL,
Opero Evo 10
20-17-3142, 20-17-3144, 20-17-3066, 20-17-3067, 20-17-3068, 20-17-3072,
20-17-3073, 20-17-3074, 20-17-3220, 20-17-3222
MY20P03-22_1.0_18.07.2019 2
Contents
Contents
1 About these operating instructions 5
1.1 Manufacturer 5
1.2 Type number and model 5
1.3 Identifying the operating instructions 6
1.4 Laws, standards and directives 6
1.5 Subject to change 6
1.6 Language 6
1.7 For your safety 6
1.7.1 Instruction, training and customer service 6
1.7.2 Basic safety instructions 6
1.7.3 Warnings 7
1.7.4 Safety markings 7
1.8 For your information 7
1.8.1 Instructions for actions 7
1.8.2 Language conventions 7
1.9 Nameplate 8
1.9.1 Information on the nameplate 9
2 Safety 10
2.1 General warnings 10
2.2 Toxic substances 11
2.3 Requirements for the rider 12
2.4 Protection for vulnerable groups 12
2.5 Data privacy 12
2.6 Personal protective equipment 12
2.7 Safety markings and safety instructions 12
2.8 Emergency 13
2.8.1 What to do in an emergency 13
2.8.2 First aid treatment 13
2.8.3 Fighting fire 13
2.8.4 Leaking fluids 14
2.8.4.1 Brake fluid 14
2.8.4.2 Oils and lubricants from the fork 14
2.8.4.3 Oils and lubricants from the rear frame
damper 14
3Overview 15
3.1 Description 16
3.1.1 Wheel and suspension 16
3.1.1.1 Valve 16
3.1.2 Suspension 16
3.1.2.1 Steel suspension fork structure 17
3.1.2.2 Air suspension fork structure 17
3.1.2.3 Structure of the FOX rear frame damper 18
3.1.2.4 Structure of the Suntour rear frame
damper 18
3.1.3 Brake system 18
3.1.3.1 Rim brake 18
3.1.3.2 Disc brake 19
3.1.3.3 Back-pedal brake 19
3.1.4 Electric drive system 20
3.1.5 Rechargeable battery 20
3.1.6 Charger 21
3.1.7 Riding light 21
3.1.8 Display 21
3.2 Proper use 22
3.3 Improper use 23
3.4 Technical data 24
3.4.1 Pedelec 24
3.4.2 Rechargeable battery 24
3.4.3 Emissions 24
3.4.4 Tightening torque 24
3.5 Environmental requirements 25
3.6 Description of controls and screens 27
3.6.1 Battery level indicator 27
3.6.2 Handlebars 27
3.6.3 Display screen buttons 27
3.6.4 Display screen indicators 27
3.6.4.1 Gear indicator 28
3.6.4.2 Battery level indicator 28
3.6.4.3 Level of assistance 28
3.6.5 Function display 28
3.6.5.1 Journey information 28
3.6.5.2 System settings and data 29
3.6.5.3 Default settings 29
3.6.5.4 Displayed speed 29
3.6.5.5 Gear shift operating mode 29
3.6.5.6 System message 29
3.6.6 Operating elements 30
4 Transporting and storing 31
4.1 Physical transport characteristics 31
4.1.1 Dimensions during transportation 31
4.1.2 Transport weight 31
4.1.3 Designated handles/lifting points 31
4.2 Transporting 31
4.2.1 Transporting the battery 32
4.2.2 Shipping the battery 32
4.2.3 Using the brake transport securing
system 32
4.3 Storing 32
4.3.1 Break in operation 33
4.3.1.1 Preparing a break in operation 33
4.3.1.2 Taking out of operation 33
5 Assembly 34
5.1 Required tools 34
5.2 Unpacking 34
5.2.1 Scope of delivery 34
5.3 Commissioning 35
5.3.1 Checking the battery 35
5.3.2 Installing the wheel in the Suntour fork 35
5.3.2.1 Installing the wheel with screw-on axle
(15 mm) 35
5.3.2.2 Installing the wheel with screw-on axle
(20 mm) 36
MY20P03-22_1.0_18.07.2019 3
Contents
5.3.2.3 Installing the wheel with a quick release
axle 37
5.3.3 Installing the wheel with a quick release 38
5.3.4 Installing the wheel in the FOX fork 39
5.3.4.1 Wheel with quick release (15 mm) 39
5.3.4.2 Adjusting the FOX quick release 40
5.3.4.3 Installing the wheel with Kabolt axles 40
5.3.4.4 Checking the stem and handlebars 40
5.3.5 Pedelec sale 41
6Operation 42
6.1 Risks and hazards 42
6.1.1 Tips for a greater range 43
6.1.2 Personal protective equipment 43
6.2 Before the first ride 44
6.2.1 Adjusting the saddle 44
6.2.1.1 Adjusting the saddle tilt 44
6.2.2 Determining the seat height 44
6.2.2.1 Adjusting the seat height with quick
release 44
6.2.2.2 Height-adjustable seat post 45
6.2.2.3 Adjusting the seat position 45
6.2.3 Adjusting the handlebars 46
6.2.3.1 Adjusting the stem 46
6.2.3.2 Adjusting the height of the handlebars 46
6.2.3.3 Turning the handlebars to the side 47
6.2.3.4 Checking the clamping force in quick
releases 47
6.2.3.5 Adjusting the quick release clamping
force 47
6.2.4 Adjusting the brake lever 47
6.2.4.1 Adjusting the pressure point on a
Magura brake lever 47
6.2.4.2 Adjusting the grip distance 48
6.2.4.3 Adjusting the grip distance on a
Magura brake lever 48
6.2.5 Adjusting the suspension of the
Suntour fork 49
6.2.5.1 Adjusting the negative deflection 49
6.2.5.2 Adjusting the air suspension fork
negative deflection 49
6.2.5.3 Adjusting the steel suspension fork
negative deflection 50
6.2.5.4 Adjusting the rebound 51
6.2.6 Adjusting the suspension of the
FOX fork 51
6.2.6.1 Adjusting the negative deflection 51
6.2.6.2 Adjusting the rebound 52
6.2.7 Setting the Suntour rear frame damper 53
6.2.7.1 Adjusting the negative deflection 53
6.2.7.2 Adjusting the rebound 53
6.2.7.3 Setting the compression 54
6.2.8 Setting the FOX rear frame damper 54
6.2.8.1 Adjusting the negative deflection 54
6.2.8.2 Adjusting the rebound 55
6.2.9 Retracting the brake linings 55
6.3 Error messages 56
6.4 Battery error message 56
6.5 Warning message 56
6.6 Error message screen 57
6.7 Accessories 58
6.7.1 Child seat 58
6.7.2 Bicycle trailers 59
6.7.3 Pannier rack 59
6.8 Before each ride 60
6.9 Check list before each ride 60
6.10 Using the kickstand 61
6.10.1 Raising the kickstand 61
6.10.1.1 Parking the pedelec 61
6.11 Using the pannier rack 61
6.12 Rechargeable battery 62
6.12.1 Side down tube battery 63
6.12.1.1 Inserting the battery 63
6.12.1.2 Removing the battery 63
6.12.2 Charging the battery 64
6.13 Electric drive system 66
6.13.1 Switching on the drive system 66
6.13.1.1 Switching on using the display 66
6.13.1.2 Switching on using the battery 66
6.13.2 Switching off the drive system 66
6.13.2.1 Switching off using the display 66
6.13.2.2 Switching off using the battery 66
6.13.3 Display 67
6.13.3.1 Using the riding light 67
6.13.4 Using the push assist system 67
6.13.4.1 Select WALK level of assistance 67
6.13.4.2 Switching on the push assist 68
6.13.4.3 Exit WALK level of assistance 68
6.13.4.4 Selecting the level of assistance 68
6.13.5 Switching the journey information 68
6.13.5.1 Opening the settings menu 69
6.13.5.2 Closing the settings menu 69
6.13.5.3 Deleting the jouney information 69
6.13.5.4 Setting the clock 70
6.13.5.5 Setting the start-up transmission 70
6.13.5.6 Changing the backlight 70
6.13.5.7 Changing the brightness 70
6.13.5.8 Changing the beep sound 71
6.13.5.9 Changing the units 71
6.13.5.10Changing the language 71
6.13.5.11Changing the font colour 71
6.13.5.12Setting the automatic gear sequence 72
6.13.5.13Change the gear shift info 72
6.13.5.14Rear derailleur reset 72
MY20P03-22_1.0_18.07.2019 4
Contents
6.14 Brake 73
6.14.1 Using the brake lever 74
6.14.2 Using the back-pedal brake 75
6.15 Suspension and damping 75
6.15.1 Adjusting the compression of the
Fox fork 75
6.15.2 Adjusting the compression of the
Fox damper 75
6.16 Gear shift 76
6.16.1 Using the derailleur gears 76
6.16.2 Using the hub gear 76
7 Cleaning and servicing 78
7.1 Cleaning after each ride 78
7.1.1 Cleaning the suspension fork 78
7.1.2 Cleaning the rear frame damper 78
7.1.3 Cleaning the pedals 78
7.2 Basic cleaning 79
7.2.1 Cleaning the frame 79
7.2.2 Cleaning the stem 79
7.2.3 Cleaning the rear frame damper 79
7.2.4 Cleaning the wheel 79
7.2.5 Cleaning the drive elements 80
7.2.6 Cleaning the chain 80
7.2.7 Cleaning the battery 80
7.2.8 Cleaning the display 81
7.2.9 Cleaning the drive unit 81
7.2.10 Cleaning the brake 81
7.3 Servicing 81
7.3.1 Servicing the frame 81
7.3.2 Servicing the stem 82
7.3.3 Servicing the fork 82
7.3.4 Servicing the drive elements 82
7.3.5 Servicing the pedals 82
7.3.6 Servicing the chain 82
7.3.7 Servicing the drive elements 82
7.4 Maintenance 82
7.4.1 Wheel 82
7.4.2 Checking the tyres 83
7.4.3 Checking the rims 83
7.4.4 Checking and adjusting the tyre
pressure 83
7.4.4.1 Dunlop valve 83
7.4.4.2 Presta valve 83
7.4.4.3 Schrader valve 83
7.4.5 Brake system 84
7.4.6 Checking the brake linings for wear 84
7.4.7 Checking the pressure point 84
7.4.8 Checking the brake discs for wear 84
7.4.9 Electrical cables and brake cables 84
7.4.10 Gear shift 84
7.4.11 Stem 84
7.4.12 USB port 84
7.4.13 Checking the belt and chain tension 85
7.5 Maintenance message 85
8 Maintenance 86
8.1 Axle with quick release 87
8.1.1 Checking the quick release 87
8.2 Adjusting the gear shift 87
8.2.1 Cable-operated gear shift, single-cable 88
8.2.2 Cable-operated gear shift, dual-cable 88
8.2.3 Cable-operated twist grip, dual-cable 88
9 Troubleshooting, fault clearance
and repair 89
9.1 Troubleshooting and fault clearance 89
9.1.1 The drive system or display do not
start up 89
9.1.2 Error messages 89
9.2 Assistance function 90
9.3 Rechargeable battery 91
9.4 Lighting 92
9.5 Display 92
9.6 Miscellaneous 93
9.7 Repair 93
9.7.1 Use original parts and lubricants only 93
9.7.2 Replacing the lighting 93
9.7.3 Setting the headlight 93
10 Recycling and disposal 94
11 Documents 95
11.1 Parts list 95
11.2 Assembly report 96
11.3 Maintenance log 98
12 Keyword index 101
13 Glossary 102
Appendix 105
I. Translation of the original EC
declaration of conformity 105
MY20P03-22_1.0_18.07.2019 5
About these operating instructions
1 About these operating instructions
Thank you for your trust!
Pegasus pedelecs are premium quality sporting
equipment – you have made an excellent choice.
Your specialist dealer has advised you and
assembled your product. Whether maintenance,
inspection, conversion or repair, your specialist
dealer will also be happy to assist you in the
future.
You receive these operating instructions with your
new pedelec. Please take a little time to become
familiar with your new pedelec and follow the tips
and suggestions in the operating instructions.
They will help you enjoy your Pegasus pedelec for
a long time to come. We hope you have fun and
wish you well on all of your rides!
These operating instructions are designed for the
rider and the operator of the pedelec to ensure
that non-professionals can use the pedelec safely.
You can download the operating instructions onto
your mobile phone at the following address, so
that you can use them when you are out riding:
https://www.pegasus-
bikes.com/service/
downloads.html
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 17959 31
E-mail: info@zeg.de
Internet: www.zeg.de
1.2 Type number and model
The operating instructions are an integral part of
pedelecs with the following type numbers:
*The type number was not available when we
went to press.
Notice
The operating instructions are not a substitute for
personal instruction by the supplying specialist
dealer.
The 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.
Instructions for the specialist dealer are highlighted in grey and
marked with a symbol. Specialist dealers have specialist
training and qualifications and are thus able to identify risks and
prevent hazards which may arise during maintenance, servicing
and repairs on the pedelec. Information for specialist staff does
not require non-professionals to take any action.
Type no. Model Pedelec type
20-17-3066 Pegasus Opero EVO 10
(Gent10) 500Wh
City and trekking
bicycle
20-17-3067 Pegasus Opero EVO 10
(Trapez10) 500Wh
City and trekking
bicycle
20-17-3068 Pegasus Opero EVO 10
(Wave10) 500Wh
City and trekking
bicycle
20-17-3072
Pegasus Opero EVO 5F
Di2 Automatic Belt
(Gent5) 500Wh
City and trekking
bicycle
20-17-3073
Pegasus Opero EVO 5F
Di2 Automatic Belt
(Trapes5) 500Wh
City and trekking
bicycle
20-17-3074
Pegasus Opero EVO 5F
Di2 Automatic Belt
(Wave5) 500Wh
City and trekking
bicycle
20-17-3142 Pegasus Opero EVO 5R
Di2 (Gent5) 500Wh
City and trekking
bicycle
20-17-3144 Pegasus Opero EVO 5R
Di2 (Wave5) 500Wh
City and trekking
bicycle
20-17-3220 Pegasus Opero EVO 5F
Di2 (Gent5) (NL) 500Wh
City and trekking
bicycle
20-17-3222 Pegasus Opero EVO 5F
Di2 (Wave5) (NL) 500Wh
City and trekking
bicycle
Table 1: Type number, model and pedelec type
MY20P03-22_1.0_18.07.2019 6
About these operating instructions
1.3 Identifying the operating
instructions
You will find the operating instructions
identification number at the bottom left-hand side
of each page. The identification number consists
of the document number, the version number and
the release date.
1.4 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/DIS 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
• EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
1.5 Subject to change
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes will be included in a new issue
of the operating instructions.
You will find any modifications to these operating
instructions:
https://www.pegasus-bikes.com/service/
downloads.html
1.6 Language
The original operating instructions are written in
German. A translation is not valid without the
original operating instructions.
1.7 For your safety
The pedelec's safety concept comprises four
elements:
• rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer
• the section on general safety
• the warnings in these operating instructions
• the safety markings on the nameplate and the
pedelec.
1.7.1 Instruction, training and customer
service
The supplying specialist dealer will provide
customer service. Contact details can be found on
the back page of these operating instructions and
on the data sheet. If you are unable to contact
your specialist dealer, you will find other specialist
dealers online at www.pegasus-bikes.com.
The rider or the operator of the pedelec will be
instructed on the pedelec's functions in person
when the supplying specialist dealer hands over
the pedelec, if not before. In particular, this
instruction will cover the pedelec's electrical
functions and correct use of the charger.
Each rider to whom this bicycle is provided must
receive instruction on the pedelec's functions. A
printed copy of these operating instructions must
be provided to each rider, who must take note of
and observe them.
1.7.2 Basic safety instructions
These operating instructions explains all general
safety instructions in Section 2.
Identification number MY20P03-22_1.0_18.07.2019
Table 2: Identification number
MY20P03-22_1.0_18.07.2019 7
About these operating instructions
1.7.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating
instructions are indicated as follows:
1.7.4 Safety markings
The following safety markings are used on the
pedelec's nameplates:
1.8 For your information
1.8.1 Instructions for actions
Instructions for actions are structured in
accordance with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)
1.8.2 Language conventions
The pedelec described in these operating
instructions may be equipped with alternative
equipment. The pedelec equipment is defined by
its respective type number. Where applicable, the
word Alternative beneath the heading indicates
alternatively used components. The following terms
are used for better legibility:
The following conventions are used in these
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. Low-risk
hazard.
Notice
May lead to material damage if ignored.
General warning
Adhere to the instructions for use
Table 3: Meaning of safety markings
DANGER
!
WARNING
!
CAUTION
!
Term Meaning
Operating
instructions
Original operating
instructions or translation
of the original operating
instructions
Pedelec Electric motor driven cycle
Motor Drive motor
Convention Use
Italics Glossary terms
SPACED Indicators on the display
screen
[Example, page
numbering]
Cross references
• Bulleted lists
MY20P03-22_1.0_18.07.2019 8
About these operating instructions
1.9 Nameplate
The nameplate is situated on the frame. You will
find the precise position of the nameplate in
Figure 2. You will find thirteen pieces of
information on the nameplate.
Figure 1: Nameplate, example
No. Designation Description
1 CE 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 this address. You can find more information in
Section 1.1.
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 further information in
Section 1.9.1.
4 Maximum continuous power The maximum continuous power is the maximum power for the electric motor output shaft
during 30 minutes.
5 Permitted total weight The permitted total weight is the weight of the fully assembled pedelec with the rider and
baggage.
6Year 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 further information in Section 1.9.3.
8 Safety markings You can find more information in Section 2.6.
9 Disposal instructions You can find more information in Section 9.
10 Area of use You can find further information in Section 1.9.4.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version 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.
12 Weight of ready-to-ride pedelec The indicated weight for a ready-to-ride pedelec refers to the weight of a pedelec at the
time of sale. The weight of each additional accessory must be added to this weight
13 Shut-off speed Speed reached by the pedelec at the moment when the current has dropped to zero or to
the no load current value.
ZEG Zweirad-Einkaufs-
Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
Typ:
20-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2019 / MJ 2020
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
MY20P03-22_1.0_18.07.2019 9
About these operating instructions
1.9.1 Information on the nameplate
Alongside the warnings, product nameplates also
contain other important information about the
pedelec:
Read the instructions
Separate collection of
electrical and electronic
devices
Separate collection of
batteries
Must not be thrown into fire
(burning prohibited)
Battery must not be opened
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 4: Relevance of safety instructions
max. 50°C
MY20P03-22_1.0_18.07.2019 9
Safety
2 Safety
2.1 General warnings
Risk of fire and explosion due to faulty battery
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BOSCH Systems
pedelecs only. This is the only way that the
battery will be protected from dangerous
overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
WARNING
!
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.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
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 immerse the battery in water.
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
CAUTION
!
MY20P03-22_1.0_18.07.2019 10
Safety
2.2 Toxic substances
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. The battery may self-ignite and explode.
Protect the battery against heat.
Never expose the battery to sustained direct
sunlight.
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 the 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.
Notice
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 from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
CAUTION
!
Intoxication from suspension oil
Suspension oil in the rear frame damper is toxic to
the touch, irritates respiratory tracts and causes
cancer, sterility and mutation in germ cells.
Never disassemble the rear frame damper.
Never allow suspension oil to come into
contact with the skin.
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from damaged or
faulty batteries. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Ventilate with fresh air and consult a doctor if
you suffer any pain or discomfort.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
Hazard for the environment due to leaking
brake fluid
The brake system contains a toxic, environmentally
harmful brake fluid. Such fluids will contaminate if
they enter the sewers or groundwater.
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
WARNING
!
CAUTION
!
MY20P03-22_1.0_18.07.2019 11
Safety
2.3 Requirements for the rider
If there are no legal requirements for riders of
electrically power-assisted cycles, we recommend
that the rider should be a minimum 15 years of
age and have experience with muscle-powered
bicycles.
The rider's physical and mental abilities must be
adequate to use a muscle-powered pedelec.
2.4 Protection for vulnerable groups
You must keep batteries and charger away from
children and people with reduced physical,
sensory or mental capabilities or lacking in
experience and knowledge.
If minors are to use the pedelec, comprehensive
instruction should be provided by or in the
presence of the legal guardians. Supervised use
should also be scheduled until it is certain that the
pedelec is being used as per these operating
instructions.
2.5 Data privacy
During maintenance, the pedelec is connected to
the diagnosis tool and data is transferred to Bosch
Pedelec Systems (Robert Bosch GmbH) about the
use of electric drive components to help improve
the product. You will find more information on the
Bosch Pedelec website
https://www.bosch-ebike.com/en/
2.6 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting clothing for
bicycles.
2.7 Safety markings and safety
instructions
The nameplate contains the following safety
markings and safety instructions:
Environmental hazard posed by oil and
lubricants from the fork
The fork contains toxic, environmentally harmful oils
and lubricants. Such fluids will contaminate if they
enter the sewers or groundwater.
The fork must be repaired immediately if oils
and lubricants are leaking out. Contact your
specialist dealer about repair.
Dispose of leaked oils and lubricants in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
Environmental hazard posed by oil and
lubricants from rear frame damper
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 oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
CAUTION
!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 5: Meaning of safety markings
MY20P03-22_1.0_18.07.2019 12
Safety
2.8 Emergency
2.8.1 What to do in an emergency
In the event of a hazard or danger 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.
2.8.2 First aid treatment
Symptoms which are caused by combustion
gases or leaking fluids require medical attention.
After inhalation
Vapours may emit if the battery is damaged or
used improperly Get into fresh air and consult a
doctor if you suffer any pain or discomfort. The
vapours may cause respiratory tract irritation.
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 or abnormalities.
After contact with eyes
Rinse eyes with plenty of water for at least
15 minutes. Protect unaffected eye. Seek medical
advice immediately.
After swallowing
Drink plenty of milk or water and induce vomiting.
Seek medical advice immediately.
2.8.3 Fighting fire
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Keep your distance if the battery becomes
deformed or starts to emit smoke.
Evacuate everyone from the immediate area of
the fire.
Contact 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.
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 6: Relevance of safety instructions
max. 50°C
Intoxication
Inhaling vapours can cause
intoxication.
Stand on the side of the fire
where the wind is coming from.
Use breathing apparatus if
possible.
WARNING
!
MY20P03-22_1.0_18.07.2019 13
Safety
2.8.4 Leaking fluids
2.8.4.1 Brake fluid
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.2 Oils and lubricants from the fork
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.3 Oils and lubricants 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. Ask a
specialist dealer for more information.
MY20P03-22_1.0_18.07.2019 15
Overview
3Overview
Figure 2: Pedelec viewed from the right, example
1Front wheel
2Fork
3 Front guard
4 Headlight
5Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Rear light and reflector
12 Rear guard
13 Rear wheel
14 Kickstand
15 Chain
16 Chain guard
17 Frame number
18 Battery and nameplate
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 16 17 18
MY20P03-22_1.0_18.07.2019 15
Overview
3.1 Description
3.1.1 Wheel and suspension
Figure 3: Components of the wheel, example of front
wheel
1 Tyre
2 Rim
3 Suspension fork head with setting wheel
4 Shock absorber
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of the shock absorber
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 either has a conventional Dunlop
valve, a Presta valve or a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series. 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.
Figure 4: Pedelec without suspension (1) and with
suspension (2) when riding over an obstacle
The suspension prevents an impact, such as one
caused by a stone lying in the bike'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. The compression
can be disabled so that a suspension fork reacts
like a rigid fork. The switch to disable the fork is
called a remote lockout.
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.
1
2
4
5
8
7
3
9
6
MY20P03-22_1.0_18.07.2019 16
Overview
3.1.2.1 Steel suspension fork structure
Figure 5: Example showing Suntour fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6). Other elements: the compression
setting (2), crown (3), Q-Loc (5), dust seal (6),
fork end for quick release (7), stanchion (8) and
spring (9)
3.1.2.2 Air suspension fork structure
The pedelec's fork features both air suspension and
a compression damper plus a rebound damper in
some cases.
Figure 6: Example showing Yari fork
You can see the following components in the
diagram: Air valve (1), valve cap (2) fork lock (3),
quick release (4) and rebound damper
adjuster (5) and the assembly groups: Air
suspension fork (A), compression damper
assembly group (B) and rebound damper
assembly group (C)
MY20P03-22_1.0_18.07.2019 17
Overview
3.1.2.3 Structure of the FOX rear frame damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 7: Example showing FOX rear frame damper
1 Guide rod eye
2Air valve
3 Setting wheel
4 Lever
5 Air chamber
6O-ring
3.1.2.4 Structure of the Suntour rear frame
damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 8: Example showing Suntour rear frame damper
1 Upper eye
2.1 Total damper length
2.2 SAG
3 Lower eye
4O-ring
5 Sleeve
6 Damper unit
7 IFP (internal floating piston)
8Air valve
9 Air chamber
10 Lockout lever
11 Rebound lever
3.1.3 Brake system
The pedelec's brake system comprises either a
hydraulic:
• rim brake on the front and rear wheels
• 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 pedelec to
a halt quickly and safely in the event of an
emergency.
3.1.3.1 Rim brake
Figure 9: Rim brake components with details; Magura
HS22 used as an example
1 Rear wheel rim brake
2 Brake booster
3 Brake lining
4Handlebars with brake lever
5 Front wheel rim brake
The rim brake stops the wheel moving when the
rider pulls the brake lever, causing two brake
linings, positioned opposite one another, to be
pressed onto the rims.
78
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Overview
The hydraulic rim brake features a locking lever.
Figure 10: Rim brake locking lever, closed (1) and open (2)
3.1.3.2 Disc brake
Figure 11: Pedelec brake system with a 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 pulled 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 pulled, the brake linings are
pressed against the brake disc and the wheel
movement is decelerated until it comes to a stop.
3.1.3.3 Back-pedal brake
Figure 12: Pedelec brake system with a back-pedal brake
– example
1 Rear wheel rim brake
2Handlebars with brake lever
3 Front wheel rim brake
4Pedal
5 Back-pedal brake
The back-pedal brake stops the movement of the
rear wheel when the rider pedals in the opposite
direction to the direction of travel.
The rim brake locking lever is not marked with any lettering.
Only a specialist dealer may set the rim brake locking lever
2
5
MY20P03-22_1.0_18.07.2019 19
Overview
3.1.4 Electric 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 13: 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.
The electric drive system comprises the following
components:
Figure 14: Diagram of electric drive system
1 Display
2 Connecting cable
3 Assistance button
4 Charger
5 Rechargeable battery
6 Chain tensioner
7 Drive unit cover
8Drive unit
9 Rear derailleur (DI2)
10 Front chainring
11 Crank
12 Gear button
13 Rechargeable battery
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the pedalling motion
of the rider. The motor force is determined by the
set level of assistance.
The pedelec does not have a separate emergency
stop or emergency shut-off button.
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.
A push assist system can be activated. The push
assist continues to drive the pedelec at walking
speed as long as the rider pushes the long
assistance lever on the handlebars. The speed
can be a maximum of 6 km/h in this case. The
drive stops when the long assistance lever is
released.
3.1.5 Rechargeable battery
The lithium ion 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. The battery also
switches to sleep mode for self-protection when
not used for a longer period.
If the remaining battery capacity is low, the
following systems are gradually switched off in the
following order:
5
MY20P03-22_1.0_18.07.2019 20
Overview
1. Pedal assistance (assistance mode
automatically switches to [ECO], then
assistance switches off. Assistance switches
to [ECO] earlier if a battery-powered light is
connected)
2. Gear shift
3. Light.
The battery's service life can be extended if it is
well maintained and, above all, stored at the
correct temperatures. 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.
The pedelec has an integrated rechargeable
battery:
Figure 15: Details of integrated battery, starting at bottom
1 On-Off button (battery)
2 Key cover
3 Charging port cover
4 Operating status and battery level indicator
3.1.6 Charger
Each pedelec is supplied with a charger. Read the
charger operating instructions.
3.1.7 Riding light
When the riding light is activated, the headlight
and the rear light are switched on together.
3.1.8 Display
The display controls the drive system with two
operating elements shifter and assistance lever
and displays the journey data. The display has a
button.
Figure 16: Overview of the display with buttons (1 and 2)
and screen (3)
Transportation temperature 5 °C - 25 °C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 5 °C - 25 °C
Ideal storage temperature 10 °C - 15 °C
Charging ambient temperature 10 °C - 30 °C
Table 7: Rechargeable battery technical data
1
2
3
4
1
2
3
MY20P03-22_1.0_18.07.2019 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.
Each pedelec is assigned a pedelec type, which
determines its proper use 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 suita-
ble 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 instruc-
tions must be com-
municated to the
riders in an age-
appropriate manner.
The cycles for chil-
dren 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 permit-
ted total weight is
being observed.
Mountain bikes are
designed for sporting
use. The design char-
acteristics 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
as well as physical fit-
ness. Use requires
the appropriate train-
ing; in particular rid-
ing 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 exces-
sively and lose con-
trol as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road sur-
face.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is char-
acterised by its light-
weight structure and
a design which is
stripped to the mini-
mum parts required
for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicy-
cle 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 there-
fore requires physi-
cal fitness.
The cargo bike is suit-
able for daily trans-
portation of loads on
public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied load-
ing conditions and
weight distributions
require special prac-
tice and skill when
braking and riding in
bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
The cargo bike
requires cautious rid-
ing. 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 trans-
portation, 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, dimin-
ished comfort and
reduced durability are
to be expected.
Table 8: Proper use
MY20P03-22_1.0_18.07.2019 22
Overview
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. The pedelec
is not suitable for the following uses:
• when the electrical drive has been manipulated
• riding with a damaged or incomplete pedelec
• riding over steps
• riding through deep water
• 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 bicy-
cles are not sports
bicycles. If used for
sports, the rider can
expect reduced riding
stability and dimin-
ished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a guard and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must be
retrofitted with light-
ing, a guard and other
fittings as specified
by national laws and
regulations before
they are used on pub-
lic roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 9: Information on incorrect use
MY20P03-22_1.0_18.07.2019 23
Overview
3.4 Technical data
3.4.1 Pedelec
3.4.2 Rechargeable battery
3.4.3 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.
3.4.4 Tightening torque
*if there is no other data on the component
Transportation temperature -20 °C - +60 °C
Storage temperature -20 °C - +70 °C
Operation temperature -10 °C - 50 °C
Charging ambient temperature 0°C - 40°C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 10: Pedelec technical data
Transportation temperature -20 °C - +60 °C
Storage temperature -20 °C - +60 °C
Charging ambient temperature 0°C - 40°C
Charge voltage 100–240 V AC
Nominal voltage 36 V DC
Table 11: Rechargeable battery 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 12: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 13: Tightening torque values
MY20P03-22_1.0_18.07.2019 24
Overview
3.5 Environmental requirements
You can be ride the pedelec within a temperature
range between 5 °C and 35 °C. The 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.
As a general rule, you should avoid temperatures
under -10 °C or over +60 °C.
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 pedelec for the first time.
Optimal operating temperature 5°C - 35°C
Transportation temperature -10 °C - 50 °C
Storage temperature -10 °C - 50 °C
Work environment temperature 15 °C - 25 °C
Charging temperature 0°C - 40°C
Table 14: 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 tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked roads, cycle
paths and firm gravel
paths and roads, and
longer sections with
moderate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads, cycle
paths and firm gravel
paths and roads, and
longer sections with
moderate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to demanding
off-road riding, sec-
tions with moderate
slopes and jumps
up to 61 cm.
Suitable for tar-
macked roads, cycle
paths and firm
gravel paths and
roads, and longer
sections with moder-
ate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to demanding
off-road riding, lim-
ited downhill use
and jumps up to
122 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to extremely
difficult off-road rid-
ing, unlimited
downhill use and
any jumps.
Table 15: Area of use
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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.
MY20P03-22_1.0_18.07.2019 26
Overview
3.6 Description of controls and
screens
3.6.1 Battery level indicator
The five green LEDs on the battery level indicator
show the battery charge status when the battery is
switched on. Each LED represents 20% of the
battery level.
You can check the battery level by looking at the
LEDs on the battery. The LED statuses are lit
( ), non-lit ( ) and flashing ( ).
The charge level for the activated battery is also
shown on the display screen. If the battery level
falls below 5%, all the LEDs on the battery level
indicator will go out. However, the battery level is
still shown on the display screen.
System errors and warnings are displayed by
various light patterns on the battery level indicator.
There is a table of system messages in the
Appendix.
3.6.2 Handlebars
Figure 17: Detailed view of pedelec from rider position,
example
1 Rear brake lever
2 Display
3Bell
4 Front brake lever
5 Assistance button
6 Fork lock on the suspension fork
7 Gear button
3.6.3 Display screen buttons
The display has two buttons.
Figure 18: Overview of the structure of the display's
operating elements
3.6.4 Display screen indicators
The display has eleven on-screen indicators:
Figure 19: On-screen indicators overview
100 - 81%
80 - 61%
60 - 41%
40 - 21%
20 - 1%
0% when the battery is not fitted to the
pedelec
0% when the battery is fitted to the
pedelec
Table 16: Charge level of the battery
1
2
3
4
56
7
Symbol Use
1 Riding light button
2 On-Off button (display)
Table 17: Operating elements overview
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Overview
3.6.4.1 Gear indicator
The rider has the choice between an automatic
and manual gear shift. The selected gear shift
type is shown on the display screen.
3.6.4.2 Battery level indicator
The battery level indicator indicates the battery
level as a percentage in a bar symbol.
3.6.4.3 Level of assistance
The higher the level of assistance, the more the
drive system assists the rider when pedalling. The
following levels of assistance are available:
3.6.5 Function display
The function display shows two different items of
information:
• journey information and
• system settings.
3.6.5.1 Journey information
The displayed journey information can be
switched. The current selected journey
information is displayed on the display screen.
You can choose:
Use
1 Unit of measure for speed
2 Current speed
3 Battery level
4Clock
5 Riding light symbol
6 Level of assistance
7 Gear shift operating mode
8 Function display
9 Gear indicator
10 Motor power used
11 System messages (if available)
Table 18: On-screen indicators overview
Screen
display Function
AUTO The electric drive system selects the ideal gear.
MANUAL The rider selects the gears.
Table 19: Symbols of the gear recommendation function
100 - 81%
80 - 61%
60 - 41%
40 - 21%
20 - 1%
0%
Table 20: Charge level of the battery
Screen display Details
HIGH High level of assistance.
NORM Normal assistance
ECO Low level of assistance
OFF Assistance off
WALK Activated push assist
Table 21: Overview of levels of assistance
Screen display Function
DST Distance travelled since the last
reset
ODO Display of the total distance
travelled (cannot be changed)
RANGE* Estimated range of the available
battery charge
TIME Trip time
AVG Average speed
MAX Maximum achieved speed
CADENCE Number of crank revolutions per
minute
CLOCK Clock
Table 22: Journey information
MY20P03-22_1.0_18.07.2019 28
Overview
3.6.5.2 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.
3.6.5.3 Default settings
3.6.5.4 Displayed speed
A selection can be made in the system settings to
determine whether the speed is displayed in
kilometres per hour [km/h] or miles per hour
[mph].
3.6.5.5 Gear shift operating mode
The rider has the choice between an automatic
and manual gear shift.
3.6.5.6 System message
The drive system monitors itself continuously and
if an error is detected, it is indicated by a system
message. The drive system distinguishes
between two system messages. Warning and
error.
Warnings
Figure 20: Example: Warning W010
Warnings are displayed between the selected
gear and the battery level indicator on the screen.
There are limitations to the system's operation,
depending on the error type. There is a table of
system messages and remedial measures in the
Appendix chapter.
Screen display Function
CLEARS Changes journey information
values
CLOCK Clock
START MODE Selects start gear
BACKLIGHT Backlight
BRIGHTNESS Sets the brightness of the
backlight
BEEP Sets the beep sound
UNIT Switches displayed unit of
measure
LANGUAGE Select the language
FONT COLOR Selects the colours
ADJUST Sets the gear shift
AUTO Pre-sets the pedalling
frequency
EXIT Returns to the main screen
Table 23: System settings
Screen display Function
BACKLIGHT ON
BRIGHTNESS 3
BEEP ON
UNIT km
LANGUAGE English
FONT COLOR White
Table 24: Default settings
Screen
display
AUTO The electric drive system selects the ideal
gear.
MANUAL The rider selects the gears.
Table 25: Symbols of the gear recommendation function
MY20P03-22_1.0_18.07.2019 29
Overview
Error messages
Figure 21: Example: Error message E010
Error messages are shown on the entire display.
There are limitations to the drive system's
operation, depending on the error type. There is a
table of error messages and remedial measures in
the Appendix chapter.
3.6.6 Operating elements
The electric drive system is operated using the
display screen (II) and the left-hand control panel
(I). The right-hand control panel (III) switches the
gears.
Figure 22: Control panel overview
Designation
1 Long assistance lever
2 Short assistance lever
3 Display
4 Long shifter
5 Short shifter
Table 26: Control panel overview
12 3
III
45
III
MY20P03-22_1.0_18.07.2019 30
Transporting and storing
4 Transporting and storing
4.2 Transporting
Take into account the weight of the ready-to-
use pedelec when transporting it.
Remove the display screen and the batteries
before transporting the pedelec.
Protect the electrical components and
connections on the pedelec from the weather
conditions with suitable protective covers.
Remove accessories such as drinking bottles
before transporting the pedelec.
You must use a suitable bicycle rack system
when transporting by car.
4.1 Physical transport
characteristics
4.1.1 Dimensions during transportation
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
4.1.2 Transport weight
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
4.1.3 Designated handles/lifting points
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
Crash caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before the pedelec is
transported.
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. Batteries may self-ignite and explode.
Never expose batteries to sustained direct
sunlight.
CAUTION
!
Oil leak if no transport securing device
The brake securing device prevents the brakes
from being applied accidentally during
transportation. This could cause irreparable
damage to the brake system or an oil leak, which
will harm the environment.
Never pull the brake lever when the wheel has
been dismounted.
Always use the transport securing system
when transporting dismounted wheels.
Notice
Oil and grease may leak from the pedelec if it is
lying flat.
If the shipping box with a pedelec is lying flat or
standing on one end, it does not provide the frame
and wheels with adequate protection against
damage.
Transport the pedelec in an upright position
only.
Bicycle rack systems which use the handlebars or
frame to hold the pedelec in an upside-down
position exert inadmissible forces on its
components during transportation. This can
cause the supporting parts to break.
Never use bicycle rack systems which use the
pedelec's handlebars or frame to hold it in an
upside-down position.
CAUTION
!
MY20P03-22_1.0_18.07.2019 31
Transporting and storing
Transport the pedelec in a dry, clean position
where it is protected from direct sunlight.
4.2.1 Transporting the battery
Batteries are subject to hazardous goods
regulations. Undamaged batteries may be
transported by private persons in road traffic.
Commercial transport requires compliance with
regulations concerning packaging, labelling and
the transportation of hazardous goods. Open
contacts must be covered and the battery
securely packaged.
4.2.2 Shipping the battery
The battery is considered a hazardous good and
only trained persons may pack and ship a battery.
Contact your specialist dealer regarding any
battery shipment.
4.2.3 Using the brake transport securing
system
Insert the transport securing devices between
the brake linings.
The transport securing device is squeezed
between the two linings.
Figure 23: Fastening the transport securing device
4.3 Storing
If the pedelec features a hydraulic seat post, fix
only the lower seat post or the frame into a fitting
stand to prevent damage to the upper seat post
and the seat post lever.
Never place a pedelec with a hydraulic seat post
upside down on the floor; otherwise you, will
damage the seat post lever.
Store the pedelec, battery and charger in a dry,
clean location.
Temperatures under -10 °C or over +60 °C
should generally be avoided. Storage at about
20 °C is beneficial to a long service life.
Notice
The specialist dealer will advise you on how to
select a suitable rack system properly and how to
use it safely.
If you ship the pedelec, we recommend that
you have it partially dismantled and packaged
properly by the specialist dealer.
Risk of fire and explosion due to high
temperatures
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. Batteries may self-ignite and explode.
Protect batteries against heat.
Never store in proximity to hot or flammable
objects.
Never expose batteries to continuous direct
sunlight and never store near heaters.
Notice
Oil and grease may leak from the pedelec if it is
lying flat.
If the shipping box with a pedelec is lying flat or
standing on one end, it does not provide the frame
and wheels with adequate protection against
damage.
Store the pedelec in an upright position only.
Optimum pedelec storage temperature 20 °C
Optimum battery storage temperature 22 °C - 26 °C
Table 27: Storage temperature for batteries, the pedelec
and charger
CAUTION
!
MY20P03-22_1.0_18.07.2019 32
Transporting and storing
4.3.1 Break in operation
If the pedelec is to be removed from service for
longer than four weeks, for the winter, for
example, 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
Store 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 20 °C are ideal.
Recharge the display battery for at least 1 hour
every 3 months.
Check 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.
MY20P03-22_1.0_18.07.2019 33
Assembly
5 Assembly
Assemble the pedelec in a clean, dry
environment.
The work environment temperature should be
between 15 °C and 25 °C.
If a fitting stand is used, it must be approved for a
maximum weight of 30 kg.
We recommend that you always disconnect the
battery from the pedelec when using the fitting
stand to reduce weight.
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
accordance with the regulations of the
authorities.
5.2.1 Scope of delivery
The pedelec was completely 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.
Injury to the eyes
Problems may arise if the settings are not made
to components properly and you may sustain
serious injuries as a result.
Always wear safety glasses to protect your
eyes during assembly.
Crushing caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery if it is not absolutely
necessary for assembly
Work environment temperature 15 °C - 25 °C
Table 28: Work environment temperature
•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
• 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.
WARNING
!
CAUTION
!
Hand injuries caused by cardboard packaging
The shipping carton is closed with metal staples.
There is a risk of puncture wounds and cuts when
unpacking and crushing the packaging.
Wear suitable hand protection.
Remove the metal staples with pliers before
the shipping carton is opened.
CAUTION
!
MY20P03-22_1.0_18.07.2019 34
Assembly
5.3 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 end
users as soon as it appears ready to ride.
For this reason, every pedelec must be
prepared, so that it is fully ready for use
immediately after being assembled.
All assembly work described in the assembly
report (see appendix) must be performed to
ensure the pedelec is ready to ride. It
describes all safety-relevant inspections, tests
and maintenance tasks for the pedelec in a
separate list.
Complete an assembly report for quality
assurance purposes.
5.3.1 Checking the battery
The battery must be checked before it is charged
for the first time.
Press 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.
Once the battery has been charged, insert it
into the pedelec.
5.3.2 Installing the wheel in the Suntour
fork
Only applies to pedelecs with this equipment
5.3.2.1 Installing the wheel with screw-on axle
(15 mm)
Insert the axle completely on the drive side.
Figure 24: Fully inserting the axle
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
Burns from hot drive
The drive cooler can become extremely hot
during use. Contact may cause burns.
Leave the drive unit to cool before cleaning.
CAUTION
!
Risk of fire and explosion due to faulty battery
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.
Never charge a faulty battery.
WARNING
!
MY20P03-22_1.0_18.07.2019 35
Assembly
Tighten the axle with a 5 mm hexagon socket
spanner to 8–10 Nm.
Figure 25: Tightening the axle
Insert the securing screw on the non-drive
side.
Figure 26: Pushing the quick release lever into the axle
Tighten the securing screw with a 5 mm
hexagon socket spanner to 5–6 Nm.
The lever is mounted.
Figure 27: Tightening the securing screw
5.3.2.2 Installing the wheel with screw-on axle
(20 mm)
Insert the axle completely on the drive side.
Figure 28: Tightening the inserted axle
Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 29: Tightening the axle
MY20P03-22_1.0_18.07.2019 36
Assembly
5.3.2.3 Installing the wheel with a quick release
axle
Insert the axle into the hub on the drive side.
Clamping version II.
Figure 30: Pushing the axle into the hub
Tighten the axle with the red handle.
Figure 31: Tightening the axle
Push the quick release lever into the axle.
Figure 32: Pushing the quick release lever into the axle
Reverse the quick release lever.
The lever is secured.
Figure 33: Securing the lever
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 cause a
detrimental 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
!
CAUTION
!
MY20P03-22_1.0_18.07.2019 37
Assembly
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 34: Perfect position for the clamping lever
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Afterwards, check the quick release lever
position and clamping force.
Figure 35: Adjusting the quick release clamping force
5.3.3 Installing the wheel with a quick
release
Before installing, ensure that the quick release
flange is extended. Open the lever completely.
Figure 36: Closed and opened flange
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 cause a
detrimental 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
!
MY20P03-22_1.0_18.07.2019 38
Assembly
Push in the quick release until you hear a
clicking sound. Make sure that the flange is
extended.
Figure 37: Pushing the quick release in
Adjust the clamping with a half-open clamping
lever until the flange reaches the fork end.
Figure 38: Adjusting the clamping
Fully close the quick release. Check the quick
release to ensure it is firmly in place and adjust
on the flange if necessary.
The lever is secured.
Figure 39: Closing the quick release
5.3.4 Installing the wheel in the FOX fork
Only applies to pedelecs with this equipment
5.3.4.1 Wheel with quick release (15 mm)
The procedure for installing the 15 x 100 mm and
15 x 110 mm quick releases is the same.
Place 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 40: Pushing the quick release in
Open the axle lever.
Turn the axle five to six complete revolutions
clockwise into the axle nut.
Close the quick release lever. The lever must
be tensioned to the point that it leaves a mark
on your hand.
The lever must be 1 to 20 mm ahead of the fork
leg in the closed position.
Figure 41: Spacing between lever and fork leg
If the lever is tensioned too little or too much
when closed in the recommended position
(1 to 20 mm ahead of the fork), the quick
release must be adjusted.
1-20 mm
MY20P03-22_1.0_18.07.2019 39
Assembly
5.3.4.2 Adjusting the FOX quick release
Figure 42: Structure of quick release from rear with (1)
axle nut lock, (2) axle nut securing screw, (3) directional
arrow, (4) axle setting value and (5) axle nut
Record the axle setting value (4) indicated by
the directional arrow (3).
Loosen the axle nut securing screw (2) with a
2.5 mm hex key by approx. four revolutions,
but do not remove the screw completely.
Turn the quick release lever to the open
position and loosen the axle by approx. four
revolutions.
Press 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.
Push the axle further forward and turn the axle
nut clockwise to increase the lever tension or
anti-clockwise to reduce the lever tension.
Reinsert the axle nut lock and tighten the screw
to 0.9 Nm (8 in-lb).
Repeat the steps for installing the axle to check
proper installation and correct adjustment.
5.3.4.3 Installing the wheel with Kabolt axles
The procedure for installing the 15 x 100 mm and
15 x 110 mm Kabolt axles is the same.
Place 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 43: Pushing the Kabolt axle in
Tighten the Kabolt axle screw to 17 Nm
(150 in-lb) with a 6 mm hex key.
5.3.4.4 Checking the stem and handlebars
Checking connections
Stand 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. Try to twist the handlebars towards the
front wheel.
The stem must not move or twist.
1
2
3
45
MY20P03-22_1.0_18.07.2019 40
Assembly
Firm hold
Place 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.
If 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.
Close the lever and check the stem is firmly in
position.
Checking the headset backlash
To check the handlebar headset backlash,
close the quick release lever on the stem.
Place 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.
The 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.
If 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.
5.3.5 Pedelec sale
Complete the data sheet on the operating
instructions envelope.
Note down the key manufacturer and its
number.
Adjust the pedelec to the rider.
Set the stand and the shifter, and show the
purchaser the settings.
Instruct the operator or rider on how to use all
the pedelec's functions.
MY20P03-22_1.0_18.07.2019 41
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 pedelec
riders. 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
and reduce your 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 on your pedelec gradually.
Practice hard braking 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
!
Risk of fire and burning 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.
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.
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 periods. The tyres in
particular can fail if exposed to a continuous load.
Decelerate the pedelec with the brakes if you
reach speeds greater than 25 km/h.
CAUTION
!
MY20P03-22_1.0_18.07.2019 42
Operation
6.1.1 Tips for a greater range
How far can a pedelec actually travel? There is no
simple answer to this question as 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 help you maximize the range.
Cadence
Pedalling frequencies higher than 50 revolutions
per minute optimise drive unit efficiency.
However, very slow pedalling uses up a great deal
of energy.
Weight
Weight should be minimised. The total weight of
the pedelec and baggage should not be
unnecessarily high.
Stopping & starting
Stopping and starting all the time is less
economical than long stretches at the same
speed, just like with a car.
Gear shift
Shifting gears correctly also makes pedelecs
more efficient: It is best to set off and ride up hills
using a low gear and switch up a gear depending
on the speed and terrain. The on-board computer
provides gear shift recommendations.
Tyre pressure
Rolling resistance can be minimised if tyres are
inflated to the right pressure. Tip: Use the
maximum permitted tyre pressure to optimize your
range.
Motor power indicator
Keep an eye on the motor power indicator on the
display screen and adjust your riding accordingly.
A long bar indicates high power consumption.
Battery & temperature
Battery performance is reduced as the
temperature drops since this increases electrical
resistance. As a result, you should expect the
range to be shorter than normal in winter.
6.1.2 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting, reflective
cycling clothing.
Notice
Moisture penetrating at low temperatures may
impair individual pedelec 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 the pedelec for
winter usage first.
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 from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
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
MY20P03-22_1.0_18.07.2019 43
Operation
6.2 Before the first ride
Only a correctly adjusted pedelec will guarantee
you 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.
6.2.1 Adjusting the saddle
6.2.1.1 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, readjust the saddle after finding the
handlebar position you prefer.
Place the saddle tilt in the horizontal position to
adjust the pedelec to your needs for initial use.
Figure 44: Horizontal saddle tilt
6.2.2 Determining the seat height
To determine the seat height 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.
Climb onto the bicycle.
Place 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,
you can adjust the length of the seat post to
your needs.
Figure 45: Optimal saddle height
6.2.2.1 Adjusting the seat height with quick
release
Open the quick release on the seat post to
change the seat height. To do so, push the
clamping lever away from the seat post.
Figure 46: Seat post quick release (3)
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
!
3
4
5
1
2
3
MY20P03-22_1.0_18.07.2019 44
Operation
The seat post quick release with clamping
lever (5) and setting bolt (4) in the open
position (1) and in the direction of the closed
position (2).
Set the seat post at the required height.
.
Figure 47: Detailed view of the seat post – examples of the
minimum insertion depth marking
To close it, push the seat post clamping lever as
far as it will go into the seat post.
Check the clamping force of quick releases.
6.2.2.2 Height-adjustable seat post
Only applies to pedelecs with this equipment
When using your seat post for the first time, you
must give it a firm push downwards to set it in
motion. This is due to the natural tendency of the
seal to repel oil from the seal surface. You only
need to do this before the first use or after a
longer period of non-use. Once you have
displaced the post through its deflection, the oil
spreads on the seal and the post begins to
function normally.
Figure 48: The seat post activation lever can be installed
either on the left (1) or the right (2) side of the handlebars
Lowering the saddle
To lower the saddle, press your hand down on the
saddle or sit on the saddle. Press the seat post
activation lever and hold it down.
Release the lever once you have reached the
required height.
Raising the saddle
Pull the seat post activation level.
Remove any pressure on the saddle and
release the lever once you have reached the
required height.
6.2.2.3 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
then 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.
Climb onto the bicycle.
Place the pedals into the vertical position
(3 o'clock position) with your feet.
The rider is sitting in the optimal sitting position
if the knee cap perpendicular line runs through
the pedal axle. If the perpendicular line crosses
behind the pedal, bring the saddle forward. If
the perpendicular line crosses in front of the
pedal, bring the saddle back. Move the saddle
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.
CAUTION
!
e
tiert w
se Position zur Be
aber in einem spätere
ochmals montieren.
Sie den mitgelieferten Winkel mit de
orrichtung und stecken Sie die Hülle in die
nvorrichtung.
der
Remotehebel
5
Oder
28
12
MY20P03-22_1.0_18.07.2019 45
Operation
within its permitted displacement range only
(marked on the saddle stay).
Figure 49: Knee cap perpendicular line
6.2.3 Adjusting the handlebars
6.2.3.1 Adjusting the stem
6.2.3.2 Adjusting the height of the handlebars
Open the clamping lever.
Pull the locking lever on the stem up, and
simultaneously pivot the handlebars into the
desired position.
You feel the locking lever click into place.
Pull out the handlebars to the required height.
Lock the quick release.
Figure 50: Open (2) and closed (1) clamping lever on the
stem; by.schulz speedlifter used as an example
The handlebar settings must only be adjusted
while the pedelec is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the
maximum tightening torque for the clamping
screws of the handlebars.
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
!
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. 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.
CAUTION
!
1
2
MY20P03-22_1.0_18.07.2019 46
Operation
6.2.3.3 Turning the handlebars to the side
Only applies to pedelecs with this equipment
Open the clamping lever.
Pull the locking lever on the stem up, and
simultaneously pivot the handlebars into the
desired position.
You feel the locking lever click into place.
Pull out the handlebars to the required height.
Lock the quick release.
Figure 51: Pushing locking lever upwards – by.schulz
speedlifter used as an example
6.2.3.4 Checking the clamping force in quick
releases
Open and close the quick releases on the stem
or the seat post.
The clamping force is sufficient if the clamping
lever can be moved easily from the open final
position into the middle and has to be pressed
with the fingers or base of the thumb from the
middle point onwards.
6.2.3.5 Adjusting the quick release clamping
force
If the clamping lever on the handlebars cannot
be moved into its final position, screw out the
knurled nut.
Tighten the knurled nut on the seat post if the
clamping lever's clamping force is not sufficient.
If you are unable to set the clamping force, the
specialist dealer will need to check the quick
release.
6.2.4 Adjusting the brake lever
6.2.4.1 Adjusting the pressure point on a
Magura brake lever
The pressure point setting is adjusted using the
twist knob.
Turn the twist knob towards the plus (+)
symbol.
The brake lever moves closer to the handlebar
grip. Re-adjust the grip distance as necessary.
The lever pressure point activates sooner.
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. 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
!
Brake failure due to incorrect setting
If the pressure point is set with brakes where the
brake linings and brake disc have reached their
wear limit, the brakes may fail and cause an
accident with injury.
Before you set the pressure point, ensure that the
brake linings and brake disc have not reached
their wear limit.
WARNING
!
MY20P03-22_1.0_18.07.2019 47
Operation
Figure 52: Using the twist knob (1) to adjust the pressure
point
6.2.4.2 Adjusting the grip distance
Figure 53: Brake lever grip distance
6.2.4.3 Adjusting the grip distance on a
Magura brake lever
Only applies to pedelecs with this equipment
Use a T25 TORX® wrench to turn the setting
screw to adjust the grip distance.
Turn the setting screw in the minus
(–) direction.
The brake lever moves closer to the handlebar
grip.
Turn the setting screw in the plus (+) direction.
The brake lever moves away from the
handlebar grip.
Figure 54: Using the setting screw (2) to adjust the
distance from the brake lever to the handlebar grip (1)
Crash caused by incorrectly set grip distance
If brake cylinders are set incorrectly or installed
wrongly, the braking power may be lost at any
time. This may cause a crash with injuries.
Once the grip distance has been set, check the
position of the brake cylinder and adjust it as
necessary.
Never correct the brake cylinder position without
special tools. Have a specialist dealer correct it.
The brake lever grip distance can be adjusted
to ensure that it can be reached more easily.
Contact your specialist dealer if the brake
handle is too far from the handlebars or is
hard to use.
WARNING
!
1
MY20P03-22_1.0_18.07.2019 48
Operation
6.2.5 Adjusting the suspension of the
Suntour fork
Only applies to pedelecs with this equipment
The following Suntour forks can be installed in this
series of models:
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.
6.2.5.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
fork caused by the weight of the rider and their
gear (e.g. a backpack), the sitting position and the
frame geometry. This sag is not caused by riding.
Each rider has a different weight and sitting
position. The sag depends on the rider's position
and weight and should be between 15% and 30%
of the maximum fork deflection, depending on
pedelec usage and preferences.
6.2.5.2 Adjusting the air suspension fork
negative deflection
Only applies to pedelecs with this equipment
The air valve is located under a cover on the
head of the left shock absorber. Screw off the
cover.
Figure 56: Screw caps in different designs
Screw a high-pressure pump onto the valve.
Pump the suspension fork up to the desired
pressure. Never exceed the recommended
maximum air pressure. Comply with the values
of the filling pressure table.
Remove the high-pressure pump.
Aion-35 Boost Air suspension fork
NCX Air suspension fork
NEX Steel suspension fork
XCM-ATB Steel suspension fork
XCM Steel suspension fork
XCR32 Air suspension fork
XCR34 Air suspension fork
Figure 55: Overview of Suntour forks
Crash caused by incorrectly set suspension
If the suspension is adjusted incorrectly, the fork
may become damaged, so that problems may
occur when steering. This will cause a crash with
injuries.
Never ride the pedelec 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 pedelec and break it in to prevent
accidents.
CAUTION
!
MY20P03-22_1.0_18.07.2019 49
Operation
.
Measure the distance between the crown and
the dust wiper of the fork. This distance is the
total deflection of the fork.
Push a temporarily attached cable tie
downward against the dust wiper of the fork.
Put on your usual bicycling clothing, including
luggage.
Sit on the pedelec in your usual riding position
and support yourself (e.g. against a wall or
tree).
Get off the pedelec without allowing it to
deflect.
Measure the distance between the dust wiper
and the cable tie. This dimension is the sag.
The sag value should be between 15% (hard)
and 30% (soft) of the total fork deflection.
Increase or reduce the air pressure until you
have reached the desired sag.
Once the sag is correct, re-tighten the blue air
cover cap clockwise.
If you cannot achieve the desired sag, you may
need to make an internal adjustment. For this
purpose, contact your specialist dealer.
6.2.5.3 Adjusting the steel suspension fork
negative deflection
Only applies to pedelecs with this equipment
You can adjust the fork by tensioning the spring to
the rider's weight and their preferred riding style.
It is not the coil spring hardness which is adjusted;
it is its pre-tensioning. This reduces the fork's
negative deflection when the rider sits on the
pedelec.
Figure 57: Negative deflection setting wheel on the
suspension fork crown
The setting wheel may be located under a
plastic cover on the suspension fork crown.
Remove the plastic cover by pulling it off
upwards.
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 reduce
it.
The ideal setting in relation to the weight of the
rider has been achieved when the shock
absorber deflects 3 mm under the stationary
load of the rider. Reattach the cover after the
adjustment.
Rider weight AION, NEX XCR 32, XCR 34
< 55 kg 35 - 50 psi 40 - 55 psi
55 - 65 kg 50 - 60 psi 55 - 65 psi
65 - 75 g 60 - 70 psi 65 - 75 psi
75 - 85 kg 70 - 85 psi 75 - 85 psi
85 - 95 kg 85 - 100 psi 85 - 95 psi
< 100 kg + 105 psi + 100 psi
Max. pressure 150 psi 180 psi
Table 29: Filling pressure table for Suntour air forks
MY20P03-22_1.0_18.07.2019 50
Operation
6.2.5.4 Adjusting the rebound
Only applies to pedelecs with this equipment
The rebound defines the speed at which the fork
rebounds after being loaded. The rebound setting
depends on the air pressure setting. Higher sag
settings require lower rebound settings.
Turn the rebound adjuster clockwise to the
closed position until it stops.
Figure 58: Suntour rebound adjuster (2) on the fork (1)
Turn the rebound adjuster anti-clockwise.
Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward during testing. Bottoming out is where
the fork rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You will hear and feel a slight knock
when this occurs.
6.2.6 Adjusting the suspension of the
FOX 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.
6.2.6.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
fork caused by the weight of the rider and their
gear (e.g. a backpack), the sitting position and the
frame geometry. This sag is not caused by riding.
Each rider has a different weight and sitting
position. The sag depends on the rider's position
and weight and should be between 15% and 20%
of the maximum fork deflection, depending on
pedelec usage and preferences.
When adjusting the sag, ensure that each
compression adjuster is in the open position, i.e.
turned clockwise until it stops.
The pressure is to be measured at an ambient
temperature of 21 to 24 °C.
Crash caused by incorrectly set suspension
If the suspension is adjusted incorrectly, the fork
may become damaged, so that problems may
occur when steering. This will cause a crash with
injuries.
Never ride the pedelec 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 pedelec and break it in to prevent
accidents.
CAUTION
!
MY20P03-22_1.0_18.07.2019 51
Operation
The air valve is located under a blue cover on
the head of the left shock absorber. Screw off
the cover anti-clockwise.
Place a high-pressure pump on the valve.
Pump the suspension fork up to the desired
pressure. Never exceed the recommended
maximum air pressure. Comply with the values
of the filling pressure table.
Remove the high-pressure pump.
Measure the distance between the crown and
the dust wiper of the fork. This distance is the
"total deflection of the fork."
Push the O-ring downward against the dust
wiper of the fork. If an O-ring is not available,
attach a cable tie to the stanchion temporarily.
Put on your usual bicycling clothing, including
luggage.
Sit on the pedelec in your usual riding position
and support yourself (e.g. against a wall or
tree).
Get off the pedelec without allowing it to
deflect.
Measure the distance between the dust wiper
and the O-ring or cable tie. This dimension is
the sag. The recommended sag value is
between 15% (hard) and 20% (soft) of the
"total fork deflection."
Increase or reduce the air pressure until you
have reached the desired sag.
Once the sag is correct, re-tighten the blue air
cover cap clockwise.
6.2.6.2 Adjusting the rebound
The rebound defines the speed at which the fork
rebounds after being loaded. The rebound setting
depends on the air pressure setting. Higher sag
settings require lower rebound settings.
Turn the rebound adjuster clockwise to the
closed position until it stops.
Figure 59: FOX rebound adjuster (1) on the fork
Turn the rebound adjuster anti-clockwise.
Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward during testing. Bottoming out is where
the fork rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You will hear and feel a slight knock
when this occurs.
Rider weight Rhythm 34 Rhythm 36
Minimum air
pressure
40 psi (2.8 bar) 40 psi (2.8 bar)
54 - 59 kg 58 psi 55 psi
59 - 64 kg 63 psi 59 psi
64 - 68 kg 68 psi 63 psi
68 - 73 kg 72 psi 67 psi
73 - 77 kg 77 psi 72 psi
77 - 82 kg 82 psi 76 psi
82 - 86 kg 86 psi 80 psi
86 - 91 kg 91 psi 85 psi
91 - 95 kg 96 psi 89 psi
95 - 100 kg 100 psi 93 psi
100 - 104 kg 105 psi 97 psi
104 - 109 kg 110 psi 102 psi
109 - 113 kg 114 psi 106 psi
Max. pressure 120 psi (8.3 bar) 120 psi (8.3 bar)
Table 30: Filling pressure table for the FOX air fork
If you cannot achieve the desired sag, you may
need to make an internal adjustment. For this
purpose, contact your specialist dealer.
MY20P03-22_1.0_18.07.2019 52
Operation
6.2.7 Setting the Suntour rear frame
damper
Only applies to pedelecs with this equipment
6.2.7.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
rear frame damper caused by the weight of the
rider and their gear (e.g. a backpack), the sitting
position and the frame geometry. This sag is not
caused by riding. Each rider has a different weight
and sitting position. The sag depends on the
rider's position and weight and should be between
25% and 30% of the maximum Rear frame
damper, depending on pedelec usage and
preferences.
Set the compression adjuster to the OPEN
position so that the sag setting is not affected.
Remove the cap on the air valve.
Attach a high-pressure damper pump to the
valve.
Adjust the air pressure of the damper so that it
corresponds to your weight.
Remove the high-pressure pump.
Measure the distance between the rubber air
chamber seal and the end of the damper. This
distance is the "total damper deflection".
Put on your usual bicycling clothing, including
luggage. Sit on the pedelec in your usual riding
position and support yourself against an object
such as a wall or tree.
Push the O-ring downward against the rubber
air chamber seal.
Get off the pedelec without allowing it to
deflect.
Measure the distance between the rubber air
chamber seal and the O-ring. This dimension is
the sag. The recommended sag value is
between 15% (hard) and 25% (soft) of the
"total damper deflection."
Increase or reduce the air pressure until you
have reached the desired sag.
6.2.7.2 Adjusting the rebound
The rebound defines the speed at which the rear
frame damper rebounds after being loaded. The
rebound setting depends on the air pressure
setting. Higher sag settings require lower rebound
settings.
Figure 60: Suntour rebound adjuster wheel (1) on the rear
frame damper
Turn the rebound adjuster wheel towards the –
symbol to increase rebounding.
Turn the rebound adjuster wheel towards the +
symbol to reduce compressive deflection
movement.
Notice
If the air pressure in the rear frame damper is
exceeded or undershot, the damper can be
permanently damaged.
Do not exceed the maximum air pressure of
300 psi (20 bar).
1
MY20P03-22_1.0_18.07.2019 53
Operation
6.2.7.3 Setting the compression
The compression damper setting of the rear frame
damper makes it possible to set the damper
according to the conditions of the ground. The
compression damper setting specifies the speed
at which the rear frame damper deflects after
being loaded.
Figure 61: Suntour compression adjuster on the rear
frame damper
Turn the compression adjuster towards the
– symbol to increase rebounding.
Turn the compression adjuster towards the
+ symbol to reduce compressive deflection
movement.
6.2.8 Setting the FOX rear frame damper
Only applies to pedelecs with this equipment
6.2.8.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
rear frame damper caused by the weight of the
rider and their gear (e.g. a backpack), the sitting
position and the frame geometry. This sag is not
caused by riding. Each rider has a different weight
and sitting position. The sag depends on the
rider's position and weight and should be between
25% and 30% of the maximum rear frame damper,
depending on pedelec usage and preferences.
Set the compression adjuster to the OPEN
position.
Adjust the air pressure of the damper so that it
corresponds to your weight.
Attach the high-pressure pump to the damper.
Slowly compress the damper over 25% of the
deflection 10 times until you have reached the
desired pressure. This equalises the air pressure
between the positive and negative air chambers,
and the pressure indication on the pump
manometer changes accordingly.
Remove the high-pressure pump.
Figure 62: FOX rear frame damper
The negative deflection (2) is the distance between
the O-ring (4) and the rubber air chamber seal (1).
The total deflection of the rear frame damper (5) is
the distance between the end of the rear frame
damper (3) and the rubber air chamber seal (1)
Measure the distance between the rubber air
chamber seal (1) and the end of the damper (3).
This distance is the "total damper deflection" (5).
Put on your usual bicycling clothing, including
luggage. Sit on the pedelec in your usual riding
position and support yourself against an object
such as a wall or tree.
Push the O-ring (4) downward against the rubber
air chamber seal (1).
Get off the pedelec without allowing it to deflect.
Measure the distance between the rubber air
chamber seal and the O-ring. This dimension is
the sag. The recommended sag value is between
25% (hard) and 30% (soft) of the "total damper
deflection" (5).
Increase or reduce the air pressure until you have
reached the desired sag.
Notice
If the air pressure in the rear frame damper is
exceeded or undershot, the damper can be
permanently damaged.
Do not exceed the maximum air pressure of 350 psi
(24.1 bar). The minimum air suspension pressure of
50 psi (3.4 bar) must be complied with.
MY20P03-22_1.0_18.07.2019 54
Operation
6.2.8.2 Adjusting the rebound
The rebound defines the speed at which the rear
frame damper rebounds after being loaded. The
rebound setting depends on the air pressure
setting. Higher sag settings require lower rebound
settings.
Figure 63: FOX rebound adjuster wheel (1) on the rear
frame damper
Turn the rebound adjuster clockwise to the
closed position until it stops.
Determine your rebound setting based on the
air pressure. Turn the rebound adjuster back
anti-clockwise by the number of clicks
specified in the table below:
6.2.9 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.
Accelerate pedelec to about 25 km/h.
Brake pedelec until it comes to a halt.
Repeat process 30–50 times.
The brake linings and brake discs are now
retracted and provide optimal braking power.
Air pressure (psi) Recommended rebound setting
< 100 Open (anti-clockwise)
100 - 120 11
120 - 140 10
140 - 160 9
160 - 180 8
180 - 200 7
200 - 220 6
220 - 240 5
240 - 260 4
260 - 280 3
280 - 300 2
Table 31: Filling pressure table for the FOX air fork
MY20P03-22_1.0_18.07.2019 55
Operation
6.3 Error messages
6.4 Battery error message
The battery indicates errors with different LED
statuses. The LED statuses are lit ( ), non-lit
( ) and flashing ( ).
6.5 Warning message
Type Status Lighting pat-
tern Remedy
System error Communication error with
the bicycle system.
Check that the charging cable is firmly and properly connected.
Contact your specialist dealer if the problem persists.
Temperature protection If the temperature exceeds
the guaranteed operating
range, the battery will switch
off.
Store battery in a cool place where there is no direct sunlight until
the battery interior temperature has fallen sufficiently.
Contact your specialist dealer if the problem persists.
Error during security
authentication
This is displayed if no
original drive unit is
connected. This is
displayed if one of the
cables is not connected.
Connect an original battery and an original drive unit.
Check the status of the cables.
Contact your specialist dealer if the problem persists.
Charge error This is displayed if an error
occurs during the charging
process.
Remove the plug connector between the battery and charger.
Press the On-Off button when only the battery is connected.
Contact your specialist dealer if the problem persists.
Battery malfunction Electrical fault in the battery. Plug the charger into the battery.
Remove the charger.
Press the On-Off switch when the battery is connected.
Contact your specialist dealer if the problem persists.
Table 32: Battery error messages
Code Cause Limitation Remedy
W011 The bike's speed cannot be
detected.
The maximum speed before
pedal assistance is provided
may be lower than normal.
Check that the speed sensor is fitted correctly.
Contact your specialist dealer if the problem persists.
W013 The torque sensor may not
have initialized completely
successfully.
Pedal assistance is possibly less
than normal.
Take your foot off the pedal.
Press the battery On-Off button and switch the system on again.
Contact your specialist dealer if the problem persists.
W032 A mechanical rear derailleur
may have been fitted instead
of an electronic one.
The pedal assistance provided in
the WALK level of assistance is
possibly less than normal.
Re-fit the front derailleur for which the system is designed.
Contact your specialist dealer if the problem persists.
Table 33: List of warnings
MY20P03-22_1.0_18.07.2019 56
Operation
6.6 Error message screen
If an error message is shown over the entire
display, follow the procedure indicated below to
reset the screen.
Press the On-Off button (battery).
Take the battery from the mount.
Contact your specialist dealer if the problem
persists.
Code Cause Limitation Remedy
E010 A system error has been detected. No pedal assistance is
provided during the ride.
Press the On-Off button (battery).
Contact your specialist dealer if the problem persists.
E013 An anomaly has been detected in
the drive unit firmware.
No pedal assistance is
provided during the ride.
Contact your specialist dealer.
E014 The speed sensor may have been
installed incorrectly.
No pedal assistance is
provided during the ride.
Contact your specialist dealer.
E020 A communication error has been
detected between the battery and
the drive unit.
No pedal assistance is
provided during the ride.
Check that the cable between the drive unit and the battery is
connected properly.
Contact your specialist dealer if the problem persists.
E021 The battery connected to the drive
unit meets the system standard but
is not supported.
No pedal assistance is
provided during the ride.
Press the On-Off button (battery).
Contact your specialist dealer if the problem persists.
E022 The battery connected to the drive
unit does not meet the system
standard.
Switch-off of all system
functions.
Press the On-Off button (battery).
Contact your specialist dealer if the problem persists.
E030 The fitted front derailleur is different
to the one configured in the system.
No assistance will be provided
during the ride.
Contact your specialist dealer.
E033 The current firmware does not
support system operation.
No pedal assistance is
provided during the ride.
Contact your specialist dealer.
E043 The display firmware may have
been corrupted.
No pedal assistance is
provided during the ride.
Contact your specialist dealer.
Table 34: List of warnings
MY20P03-22_1.0_18.07.2019 57
Operation
6.7 Accessories
We recommend a parking stand into which either
the front 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.
6.7.1 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 and electrical
cables are adjusted as necessary, the rider's
freedom of movement is not restricted and the
pedelec's permitted total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the 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
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 35: Accessories
Crash caused by incorrect child seat
Neither the pannier rack nor the pedelec down
tube are suitable for 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 total weight of the pedelec.
CAUTION
!
MY20P03-22_1.0_18.07.2019 58
Operation
cables, brake cables, hydraulic and electrical
cables are adjusted as necessary, the rider's
freedom of movement is not restricted and the
pedelec's permitted total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
6.7.2 Bicycle trailers
A pedelec which is approved for towing a trailer
will bear an appropriate adhesive label. Only
bicycle trailers with a support load and total mass
which do not exceed the permitted values may be
used.
Figure 64: 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.
6.7.3 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 will make sure that the fastening
mechanism for the rack is suitable for the pedelec
and that all components are installed and firmly
fastened. They will also ensure that shift cables,
brake cables and hydraulic and electrical lines are
adjusted as necessary, the rider's freedom of
movement is not restricted and the permitted total
weight of the pedelec 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 brake may not work sufficiently if there is an
excessive trailer 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 notes 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
!
MY20P03-22_1.0_18.07.2019 59
Operation
6.8 Before each ride 6.9 Check list before each ride
Check the pedelec before each ride.
Do not use the pedelec if there is evidently
something wrong with it.
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.
CAUTION
!
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 pedelec 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.
Use body weight to compress suspension system. Adjust to
the optimum sag value if suspension is too soft.
If quick releases are used check them to make sure that
they are fully closed in their end position. If quick release
axle systems are used, make sure that all attachment
screws are tightened to the correct torque.
Be alert to any unusual operating sensations when braking,
pedalling or steering.
Check that the ABS indicator lamp lights up correctly on
pedelecs with an ABS system.
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Operation
6.10 Using the kickstand
6.10.1 Raising the kickstand
Before the ride, raise the kickstand completely
with your foot.
6.10.1.1 Parking the pedelec
Use your foot to lower the kickstand completely
before parking.
Park the pedelec carefully and check that it is
stable.
6.11 Using the pannier rack
Distribute the baggage as evenly as possible
on the left- and right-hand side of the pedelec.
We recommend the use of panniers and
baggage baskets.
Crash caused by a lowered kickstand
The kickstand does not fold up automatically.
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 and the pedelec
may topple over.
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 pedelec's 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 permitted total weight when
loading the pedelec.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
CAUTION
!
MY20P03-22_1.0_18.07.2019 61
Operation
6.12 Rechargeable battery
Risk of fire and explosion due to faulty battery
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BOSCH Systems
pedelecs only. This is the only way that the
battery will be protected from dangerous
overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
Avoid wide temperature fluctuations.
WARNING
!
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from a damaged or
faulty battery. Excessive temperatures can also
cause liquid to leak from the battery and the
battery will become damaged. Such liquids can
irritate the airways and cause burns.
Avoid any contact with leaked liquids:
- Immediately consult a doctor if liquid comes
into contact with eyes or causes any
discomfort.
- If liquid comes into contact with the skin,
rinse off immediately with water.
- Ventilate the room well.
Protect the battery against heat over 60 °C,
e.g. against permanent direct sunlight.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
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 immerse the battery in water.
Never clean the battery with a pressure
washer.
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
CAUTION
!
MY20P03-22_1.0_18.07.2019 62
Operation
Switch off the battery and the drive system
before removing or inserting the battery.
6.12.1 Side down tube battery
Switch off the battery and the drive system
before removing or inserting the battery.
6.12.1.1 Inserting the battery
Figure 65: Positioning battery (1) on mount (2)
Place the battery on the contacts in its lower
mount. Push the battery inwards.
There is an audible clicking noise.
Secure the battery by closing. Remove key.
Check the inserted battery to make sure it is
fastened and firmly in place.
Figure 66: Closed key cover (1) and charge cap (2)
Before setting off, ensure that the key cover
and charge cap are closed.
6.12.1.2 Removing the battery
Remove key cover.
Insert key into the key cylinder in the battery
mount. The position of the key has no effect on
the battery mount. You can insert the key in
any position. You cannot remove the key if it is
not in the insert position.
Figure 67: Removing and inserting the down tube battery
Turn the key in a clockwise direction to unlock
the battery (1) and press the key into place (2).
The battery is unlocked.
Support the battery in your hand to ensure that
it won't fall out. Remove the key and re-insert
the battery lock cover.
Remove the battery using removal handle.
Notice
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 from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
2
1
1
2
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Operation
6.12.2 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.
If pedelec features two batteries, charging for
both batteries is started via pannier rack
battery.
Remove the rubber cover from the battery.
Connect the mains plug of the charger to a
normal domestic, grounded socket.
Connect the charging cable to the battery's
charging port.
The charging process starts automatically.
The LED light on the charger will light up once
charging starts.
Figure 68: LED light on the charger
Fire and explosion due to defective batteries
The safety electronics on damaged or faulty
batteries may fail. The residual voltage can cause
a short circuit. Batteries may self-ignite and
explode.
Never charge a faulty battery
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.
WARNING
!
CAUTION
!
Connection data 230 V, 50 Hz
Notice
Check that mains voltage is correct. The
power source voltage must match the voltage
indicated on the charger nameplate. Chargers
labelled 230 V may also be operated at 220 V.
1
MY20P03-22_1.0_18.07.2019 64
Operation
The LED light on the charger has three statuses:
You can check the battery level by looking at
the LEDs on the battery. The LED statuses are
lit ( ), non-lit ( ) and flashing ( ).
You can check the current charging status by
pressing the battery's On-Off switch.
The charging process is complete when the
LEDs on the operating status and battery level
indicator go out.
Status Meaning
Lit The charger is recharging the
battery.
Flashing There is a charging error.
Switched off Battery disconnected
Risk of fire and explosion caused by damaged
batteries
The safety electronics on damaged or faulty
batteries may fail. The residual voltage can cause
a short circuit. Batteries may self-ignite and
explode.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish damaged batteries with
water or allow them to come into contact with
water.
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.
CAUTION
!
100 - 81%
80 - 61%
60 - 41%
40 - 21%
20 - 1%
0% when the battery is not fitted
to the pedelec
0% when the battery is fitted to
the pedelec
Table 36: Charge level of the battery
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Operation
6.13 Electric drive system
6.13.1 Switching on the drive system
A sufficiently charged battery has been inserted
into the pedelec.
Never place your feet on the pedals when
switching on. If the pedals are moved when
switching on, a system error is caused.
The battery is firmly positioned. The key has been
removed.
The system cannot be switched on while
charging.
There are 2 options for switching on the drive
system:
6.13.1.1 Switching on using the display
Press and hold the On-Off button (display) for
2 seconds.
6.13.1.2 Switching on using the battery
Figure 69: On-off button on the battery
Press the On-Off button (battery) briefly.
The LED light will light up and indicate the
remaining battery capacity.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force.
6.13.2 Switching off the drive system
The system switches off automatically ten minutes
after the last command.
There are 2 options for switching off the drive
system:
6.13.2.1 Switching off using the display
Press and hold the On-Off button (display) for
2 seconds.
6.13.2.2 Switching off using the battery
Press and hold the On-Off button (battery) for
6 seconds.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force.
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
!
MY20P03-22_1.0_18.07.2019 66
Operation
6.13.3 Display
The display screen is operated using the display
screen (II) and the left-hand control panel (I). The
right-hand control panel (III) switches the gears.
Figure 70: Control panel overview
6.13.3.1 Using the riding light
The drive system must be switched on.
Press the light button.
The light is switched on. The riding light symbol
is shown on the screen.
Press the light button.
The light is switched off
6.13.4 Using the push assist system
The push assist helps the rider to push 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. We recommend using first gear for cycling
uphill to protect the drive.
6.13.4.1 Select WALK level of assistance
Push the long assistance lever for about
2 seconds.
The level of assistance WALK is displayed.
If a warning is sounded during switchover, it is
impossible to switch to the WALK level of
assistance. This may be due to the current
speed not being 0 km/h, pressure being
applied to the pedals or similar.
Release the long assistance lever.
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 pedelec 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 the display as a handle. You may
irreparably damage the display if you use it to
lift the pedelec.
Designation
1Long assistance lever
2Short assistance lever
3Display
4Long shifter
5Short shifter
Table 37: Control panel overview
CAUTION
!
12 3
III
45
III
Injury caused by pedals
The pedals turn when using the push assist due
to the system design.
You must steer the pedelec securely with both
hands when using push assist.
Allow for enough freedom of movement for the
pedals.
CAUTION
!
MY20P03-22_1.0_18.07.2019 67
Operation
6.13.4.2 Switching on the push assist
Push the long assistance lever to switch on the
push assist system.
Switching off the push assist
Release the long assistance lever to switch off
the push assist system.
6.13.4.3 Exit WALK level of assistance
Push the short assistance lever to change
from the WALK level of assistance to the level
of assistance last used.
If the long assistance lever is not pushed for
longer than one minute, the level of assistance is
reset to the level of assistance used previously.
6.13.4.4 Selecting the level of assistance
The following levels of assistance are available:
Push the long assistance lever briefly to
increase the level of assistance.
Push the short assistance lever to reduce the
level of assistance.
6.13.5 Switching the journey information
The displayed journey information can be
switched.
Press the button (display) repeatedly until the
desired item of journey information is displayed.
*1 The figures for possible journey distances are
estimated and should be used for reference
purposes only.
*2 These data are displayed as follows:
1. RANGE
2. HIGH
3. NORM
4. ECO
*3 Optional screen display.
Screen display Details
BOOST High level of assistance.
TRAIL Normal assistance
ECO Low level of assistance
OFF Assistance off
WALK Activated push assist
Table 38: Overview of levels of assistance
Screen display Function
DST Distance travelled since the last reset
ODO Display of the total distance travelled
(cannot be changed)
RANGE Estimated range of the available battery
charge *1
TIME Possible journey time *1 *2 *3
AVG Average speed *3
MAX Maximum achieved speed *3
CADENCE Number of crank revolutions per minute
*3
Table 39: Journey information
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Operation
6.13.5.1 Opening the settings menu
You can only change the settings when you stop.
Press the button (display).
Push the long assistance lever or short
assistance lever briefly to move the cursor on
the menu.
6.13.5.2 Closing the settings menu
Push the long assistance lever or short
assistance lever briefly repeatedly until EXIT
is highlighted.
Press the button (display).
The settings menu is closed.
6.13.5.3 Deleting the jouney information
The TRIP distance completed can be deleted.
TIME, AVG and MAX are also deleted if the
distance is deleted.
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
CLEAR is displayed.
Press the button (display).
You will see three selection options:
* Elements and default values which are reset
by a [reset]:
Push the long assistance lever or the short
assistance lever briefly until TRIP is
highlighted.
Press the button (display).
The data have been cleared.
The display screen switches back to the start
screen.
Screen display Function
CLEAR Clears the settings
CLOCK Setting the clock
START MODE Adjusts the start-up
transmission
BACKLIGHT Adjusts the backlight
BRIGHTNESS Adjusts display screen
brightness
BEEP Switches the beep on and off
UNIT Adjusts journey distance unit:
km/h or m.p.h.
LANGUAGE Adjusts language
FONT COLOR Makes colour setting
ADJUST Adjusts the electronic gear shift
GEAR SETTING Adjusts the gear shift point
GEAR SHIFT INFO Switches the gear
recommendation on and off
RD PROTECTION RESET Activates the rear derailleur
reset
EXIT Returns to the main screen
Table 40: Journey information
Screen display Function
EXIT Returns to the menu list display screen
DST Deletes the journey information
DEFAULT Resets the bicycle computer settings *
Table 41: Journey information change options
Function Setting
Backlight ON
Beep ON
Unit km
Language English
Brightness 3
Font color White
Table 42: Journey information change options
MY20P03-22_1.0_18.07.2019 69
Operation
6.13.5.4 Setting the clock
Configure the clock settings. First set the hours
and then the minutes. You can change the values
quickly by keeping the long assistance lever or
the short assistance lever pressed down.
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
CLOCK is displayed.
Press the button (display).
The set time is displayed. The hour indicator is
highlighted.
Push the long assistance lever or the short
assistance lever repeatedly until the required
hour is displayed.
Press the button (display).
The minute indicator is highlighted.
Push the long assistance lever or short
assistance lever repeatedly briefly until the
required minute is displayed.
Press the button (display).
The display screen switches back to the start
screen.
6.13.5.5 Setting the start-up transmission
When the start-up [Start mode] is enabled, the
selected start-up transmission is used when the
pedelec is started. The transmission may
automatically shift to the pre-set gear if you set off
after being stationary.
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
START MODE is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever repeatedly until the required
setting is highlighted.
Press the button (display).
The selected start-up transmission is
activated.
The display screen switches back to the start
screen.
6.13.5.6 Changing the backlight
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
BACKLIGHT is displayed.
Press the button (display).
You will see three selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The light settings have been changed.
The display screen switches back to the start
screen.
6.13.5.7 Changing the brightness
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
BRIGHTNESS is displayed.
Press the button (display).
You can choose from 5 brightness options.
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The brightness has been changed.
The display screen switches back to the start
screen.
Screen display Function
OFF Start-up transmission deactivated
[1 - 11] Gear 1 - 11
Table 43: Start-up transmission change options
Screen display Function
ON Light always on.
OFF Light always off.
MANUAL Is switched on and off with the battery-
powered light
Table 44: Light change options
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Operation
6.13.5.8 Changing the beep sound
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until BEEP
is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The beep sound has been changed.
The display screen switches back to the start
screen.
6.13.5.9 Changing the units
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until UNIT
is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The unit has been changed.
The display screen switches back to the start
screen.
6.13.5.10 Changing the language
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until
LANGUAGE is displayed.
Press the button (display).
You will see six selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
language is highlighted.
Press the button (display).
The language is changed.
The display screen switches back to the start
screen.
6.13.5.11 Changing the font colour
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until FONT
COLOR is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The FONT COLOR has been changed.
The display screen switches back to the start
screen.
Screen display Function
ON Beep sound always on.
OFF Beep sound always off.
Table 45: Beep sound change options
Screen display Function
KM Unit in km.
MILE Unit in miles
Table 46: Units change options
Language
ENGLISH
Français
Deutsch
Nederlands
Italiano
Español
Table 47: Language change options
Screen display Function
WHITE Black letters on a white background
BLACK White letters on a black background
Table 48: Font colour change options
MY20P03-22_1.0_18.07.2019 71
Operation
6.13.5.12 Setting the automatic gear sequence
6.13.5.13 Change the gear shift info
You can choose whether gear shift info is
displayed or not.
The settings menu is open.
Push the long assistance lever or short
assistance lever briefly repeatedly until SHIFT
INFO is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The gear shift info has been changed.
The display screen switches back to the start
screen.
6.13.5.14 Rear derailleur reset
The rear derailleur protection function will trigger
to protect the system if the pedelec is exposed to
a severe impact – due to a fall, for example. The
connection between the motor and the link is
interrupted instantly, rendering the rear derailleur
inoperable.
If you open RD PROTECTION RESET, the
connection between the motor and link is re-
established and the rear derailleur function reset.
The settings menu is open.
Press the button (display) repeatedly until
RD PROTECTION RESET is displayed.
Press the button (display).
You will see two selection options:
Push the long assistance lever or the short
assistance lever briefly until the required
function is highlighted.
Press the button (display).
The display screen switches back to the start
screen.
Turn the crank.
The connection between the motor and the link
is restored.
You can configure the gear shift point in the
SHIFT SETTING menu option. Special knowledge
and tools are required for setting the gear shift.
These settings must only be made by a specialist
dealer.
Screen display Function
ON Activate gear shift info
OFF Deactivate gear shift info
Table 49: Gear shift info change options
Screen display Function
OK Rear derailleur reset is in progress
CANCEL Returns to the menu list display screen
Table 50: Rear derailleur reset change options
MY20P03-22_1.0_18.07.2019 72
Operation
6.14 Brake
Hydraulic fluid can be fatal if it is swallowed
and penetrates into the respiratory system
Hydraulic fluid may leak out after an accident or
due to material fatigue. Hydraulic fluid can be
fatal if swallowed and inhaled.
First aid treatment
Wear gloves and safety goggles as protective
equipment. Keep unprotected persons away.
Remove those affected from the danger area to
fresh air. Never leave those affected unattended.
Ensure sufficient ventilation.
Immediately remove clothing items contaminated
with hydraulic fluid.
Serious slip hazard due to hydraulic fluid
leakage.
Keep away from naked flames, hot surfaces and
sources of ignition.
Avoid contact with skin and eyes.
Do not inhale vapours or aerosols.
After inhalation
Take in fresh air; consult doctor if any pain or
discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor if any 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.
Consult eye doctor if pain or discomfort
continues.
DANGER
!
After swallowing
Rinse out mouth with water. Never induce
vomiting! Risk of aspiration!
Place a person lying on their back who is
vomiting in a stable recovery position on their
side. Seek medical advice immediately.
Environmental protection measures
Never allow hydraulic fluid to flow into the
sewage system, surface water or groundwater.
Notify the relevant authorities if fluid penetrates
the ground or pollutes water bodies or the
sewage system.
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.
DANGER
!
WARNING
!
MY20P03-22_1.0_18.07.2019 73
Operation
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.
6.14.1 Using the brake lever
Figure 71: Front (2) and rear (1) brake lever; Shimano
brake used as an example
Push the left brake lever for the front wheel brake
and the right lever for the rear wheel brake until
the desired speed is reached.
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 disc.
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.
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 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 it no longer brakes as
normal. Consult a specialist dealer.
CAUTION
!
MY20P03-22_1.0_18.07.2019 74
Operation
6.14.2 Using the back-pedal brake
Only applies to pedelecs with this equipment
The best braking effect is achieved if the pedals
are in the 3 o'clock and 9 o'clock position when
braking. To bridge the free travel between the
riding movement and the braking movement, it is
recommendable to pedal a little beyond the
3 o'clock and 9 o'clock position before you pedal
in the opposite direction to the direction of travel
and start braking.
Pedal in the opposite direction to the direction of
travel until the desired speed has been reached.
6.15 Suspension and damping
6.15.1 Adjusting the compression of the
Fox 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 72: FOX compression adjuster with the OPEN (1)
and HARD (2) positions
Compression damping is lowest in the OPEN
position, making the fork feel softer. Use the
HARD position if you want to the fork feel stiffer
and you are riding on soft ground. The lever
positions between the OPEN and HARD
positions enable fine adjustment of compression
damping.
We recommend setting the lever of the compres-
sion adjuster to the OPEN mode position first.
6.15.2 Adjusting the compression of the
Fox damper
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to make
quick adjustments to the suspension behaviour of
the damper to suit changes in terrain. It is intended
for adjustments made during the ride.
Figure 73: FOX compression adjuster on the rear frame
damper with the OPEN (1), MEDIUM (2) and HARD (3)
positions
Use the OPEN position for rough descents, the
MEDIUM position for rough terrain and the HARD
position for efficient climbing. First set the
compression adjuster to the OPEN position.
Figure 74: Fine adjustment of the OPEN position is made
using the adjuster (4)
The FOX rear frame damper features fine
adjustment for the OPEN position.
We recommend that fine adjustments be made
when the compression adjuster is in the MEDIUM
or HARD position.
Pull out the adjuster.
Turn the adjuster to position 1, 2 or 3. Setting 1 is
for the softest riding performance, whereas 3 is
for the hardest.
Press the adjuster in to lock in the setting.
1
2
1
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Operation
6.16 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.
It is advisable to stop pedalling briefly when
changing gears. This makes it easier to switch
gears and reduces wear on the drivetrain.
6.16.1 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 75: 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 the rear derailleur if the gear change
blocks.
6.16.2 Using the hub gear
Only applies to pedelecs with this equipment
III
1
22
1
Crash caused by incorrect use
If the rider applies too much pressure on the
pedals during a gear change and activates the
shifter or changes several gears at a time, their
feet may slip from the pedals. As a result, the
pedelec may flip over or fall, which may cause
injury.
Switching down several gears to a low gear may
cause the twist grip outer sleeve to suddenly
come off. This will not have an adverse effect on
the twist grip's correct functioning since the outer
guide returns to its original position after the gear
change is complete.
Apply little pressure on the pedals while changing
gears.
Never change more than one gear at a time.
Notice
The interior hub is not completely waterproof. If
water gets into the hub, it may rust and the gear
switch function may no longer function as a result.
Never use the pedelec in places where water
may get into the hub.
In rare cases, noises may be heard from the rear
derailleur in the hub interior after a gear change.
This is normal when gears are changed.
Do not detach the hub. If you need to detach it,
contact your dealer.
CAUTION
!
MY20P03-22_1.0_18.07.2019 76
Operation
.
Figure 76: Example; Shimano Nexus gear shift: Twist
grip (1) for the hub gear with its screen (3), the direction of
rotation to switch up a gear (2) and the direction of
rotation to switch down a gear (4)
Turn the twist grip.
The gear shift switches the gear.
The number on the screen display shows the
changed gear.
MY20P03-22_1.0_18.07.2019 77
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
The following servicing measures must be
performed regularly. Servicing can be performed
by the operator and rider. In case of any doubt,
consult the specialist dealer.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits on the stanchions
and deflector seals with a damp cloth.
Check the stanchions for dents, scratches,
staining or leaking oil.
Check the air pressure.
Lubricate the dust seals and stanchions.
7.1.2 Cleaning the rear frame damper
Remove dirt and deposits from the damper
body with a damp cloth.
Check rear frame damper for dents, scratches,
staining or leaking oil.
7.1.3 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
Clean the suspension fork and, if
necessary, rear frame damper after each ride
Cleaning the battery once a month
Chain (mainly tarmacked road) Every
250–300 km
Basic cleaning and preservation of all
components
at least every six
months
Clean the charger at least every six
months
Clean and lubricate the height-adjustable
seat post 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 suspension fork and, if necessary,
rear frame damper for wear and ensure
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
MY20P03-22_1.0_18.07.2019 78
Cleaning and servicing
7.2 Basic cleaning
Remove battery and display before basic
cleaning.
7.2.1 Cleaning the frame
Soak dirt stains on the frame with dish-washing
detergent if the dirt is thick and ingrained.
After leaving it to soak for a time, remove the
dirt and mud with a sponge, brush and
toothbrush.
Use a watering can or your hand to rinse the
frame to finish off.
Service the frame after cleaning.
7.2.2 Cleaning the stem
Clean stem with a cloth and soapy water.
Service the stem after cleaning.
7.2.3 Cleaning the rear frame damper
Clean rear frame damper with a cloth and
soapy water.
7.2.4 Cleaning the wheel
Check the tyres, rims, spokes and spoke
nipples for any damage when cleaning the
wheel.
Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
Clean the rim with a sponge.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairing
the pedelec. 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 into 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 steam jet.
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
!
MY20P03-22_1.0_18.07.2019 79
Cleaning and servicing
7.2.5 Cleaning the drive elements
Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
Clean coarse dirt with a brush after soaking for
a short time.
Wash down all parts with dish-washing
detergent and a toothbrush.
Service the drive elements after cleaning.
7.2.6 Cleaning the chain
Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
Dampen a cloth with soapy water. Place the
cloth on the chain.
Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
If the chain is still dirty afterwards, clean it with
lubricant.
Service the chain after cleaning.
7.2.7 Cleaning the battery
Clean the battery electrical connections with a
dry cloth or brush only.
Wipe off the decorative sides with a damp
cloth.
Notice
Never use aggressive (acid-based) cleaners,
rust removers or degreasers when cleaning
the chain.
Do not 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 high-pressure
water device, water jet or compressed air.
Keep the contacts clean and dry.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the pedelec before
cleaning.
Notice
Do not clean the battery with solvents, such as
thinners, alcohol, oil and corrosion protection,
or with cleaning agents.
CAUTION
!
MY20P03-22_1.0_18.07.2019 80
Cleaning and servicing
7.2.8 Cleaning the display
Carefully clean the display with a damp, soft
cloth.
7.2.9 Cleaning the drive unit
Carefully clean the drive unit with a damp, soft
cloth.
7.2.10 Cleaning the brake
Clean brake and brake discs with a brush,
water and dish-washing detergent.
Clean brake discs thoroughly with brake
cleaner or spirit.
7.3 Servicing
7.3.1 Servicing the frame
Dry frame after cleaning.
Spray with care oil. Clean off the care oil again
after a short time.
Notice
If water enters into the display screen, it will be
permanently damaged.
Never immerse the display in water.
Never clean with a high-pressure water
device, water jet or compressed air.
Never use cleaning agents.
Remove the display from the pedelec before
cleaning.
Burns from hot drive
The drive cooler can become extremely hot
during use. Contact may cause burns.
Leave the drive unit to cool before cleaning.
Notice
If water enters into the drive unit, the unit will be
permanently damaged.
Never immerse the drive unit in water.
Never clean with a high-pressure water
device, water jet or compressed air.
Never use cleaning agents.
Never open.
CAUTION
!
Brake failure due to water penetration
The brake seals are unable to withstand high
pressures. Damaged brakes can fail and cause
an accident with injury.
Never clean the pedelec with compressed air
or a high-pressure water device.
Take great care when using a hosepipe. Never
point the water jet directly at the seal section.
Required tools and cleaning agents:
• Cloths
• Toothbrushes
• Dish-washing liquid
• Care oil for frames
• Silicone or Teflon oil
• Acid-free lubricating grease
• Fork oil
• Chain oil
• Degreaser
• Spray oil
•Teflon spray
WARNING
!
MY20P03-22_1.0_18.07.2019 81
Cleaning and servicing
7.3.2 Servicing the stem
Apply silicone or Teflon oil to the stem shaft
tube and the quick release lever pivot point.
If you have speedlifter Twist, also apply oil to
the unlocking bolt using the groove in the
speedlifter body.
Apply a little acid-free lubricant grease
between the stem quick release lever and the
sliding piece to reduce the quick release lever
operating force.
7.3.3 Servicing the fork
Treat the dust seals with fork oil.
7.3.4 Servicing the drive elements
Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
Clean coarse dirt with a brush after soaking for
a short time.
Wash down all parts with dish-washing
detergent and a toothbrush.
7.3.5 Servicing the pedals
Treat with spray oil after cleaning.
7.3.6 Servicing the chain
Grease the chain thoroughly with chain oil after
cleaning.
7.3.7 Servicing the drive elements
Service front and rear derailleur articulated
shafts and jockey wheels with Teflon spray.
7.4 Maintenance
The following maintenance measures must be
performed on a regular basis. They can be carried
out by the operator and rider. In case of any doubt,
consult the specialist dealer.
7.4.1 Wheel
Check tyre wear.
Check the tyre pressure.
Check 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.
Check the tension of the spokes.
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
!
MY20P03-22_1.0_18.07.2019 82
Cleaning and servicing
7.4.2 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.
7.4.3 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.
Worn rims must be replaced by a specialist
dealer.
We recommend that you also replace the rims
at the same time as every second brake lining
replacement.
7.4.4 Checking and adjusting the tyre
pressure
7.4.4.1 Dunlop valve
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.
Unscrew and remove the
valve cap.
Connect the bicycle pump.
Pump up the tyre slowly and
pay attention to the tyre
pressure in the process.
Correct the tyre pressure
according to specifications in
the Pedelec pass.
If the tyre pressure is too
high, unfasten the union nut,
let out air and tighten the
union nut again.
Remove the bicycle pump.
Screw the valve cap tight.
Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.4.2 Presta valve
It is recommendable to
use a bicycle pump with a
pressure gauge. The
operating instructions for
the bicycle pump must be
adhered to.
Unscrew and remove
the valve cap.
Open the knurled nut
around four turns.
Carefully apply the
bicycle pump so that the
valve insert is not bent.
Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
Remove the bicycle pump.
Tighten the knurled nut with your fingers.
Screw the valve cap tight.
Screw the rim nut gently against the rim with the
tips of your fingers.
7.4.4.3 Schrader valve
It is recommendable to use
a bicycle pump with a
pressure gauge. The
operating instructions for the
bicycle pump must be
adhered to.
Unscrew and remove the
valve cap.
Connect the bicycle
pump.
Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
Remove the bicycle pump.
Screw the valve cap tight.
Screw the rim nut gently against the rim with
the tips of your fingers.
1
MY20P03-22_1.0_18.07.2019 83
Cleaning and servicing
7.4.5 Brake system
The maintenance interval for the brake depends on
the weather conditions and how frequent the
pedelec is used. If the pedelec is used under
extreme conditions such as rain, dirt or high
mileage, maintenance must be performed more
frequently.
7.4.6 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
Check 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.
Push 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. If they have, a specialist dealer will need
to replace the brake linings.
7.4.7 Checking the pressure point
Push brake lever and hold several times.
If you are unable to clearly detect the pressure
point and it changes, a specialist dealer needs
to vent the brake.
7.4.8 Checking the brake discs for wear
Check that the brake disc is no less than
1.8 mm at any point.
The brake discs have not reached the wear
limit. If they have, a specialist dealer will need
to replace brake discs.
7.4.9 Electrical cables and brake cables
Check all visible electrical cables and cables
for damage. If the sheathing is compressed, for
example, the pedelec will need to be removed
from service until the cables have been
replaced.
Check all electrical cables and cables to make
sure they are fully functional.
7.4.10 Gear shift
Check the gear shift and the shifter or the twist
grip setting and adjust it as necessary.
7.4.11 Stem
The stem and quick release system should 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.
Check for wear and signs of corrosion
(maintain with an oily cloth) and for oil leaks.
7.4.12 USB port
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 the
hydraulic brake system on a regular basis and
replace if necessary.
CAUTION
!
Notice
Any moisture which enters through the USB port
may trigger a short circuit in the display.
Regularly check the position of the cover on the
USB port and adjust it as necessary.
MY20P03-22_1.0_18.07.2019 84
Cleaning and servicing
7.4.13 Checking the belt and chain tension
Check the chain tension in three or four
positions, turning the crank a full revolution.
Figure 77: Checking the chain tension
If the chain can be pushed more than 2 cm, the
chain or drive belt will need to be tensioned
again by the specialist dealer.
If the chain or the drive belt can only be pushed
up and down less than 1 cm, you will need to
slacken the chain or the drive belt.
The optimum chain tension is achieved if the
chain or the drive belt 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.
If a hub gear is featured, the rear wheel must
be pushed backwards or forwards to tighten
the chain. Only a specialist should do this.
Check the handlebar grip is firmly in position.
7.5 Maintenance message
Figure 78: Maintenance message (1)
The maintenance message informs the user that
the pedelec needs maintenance. A symbol is
shown on the display if the pedelec reaches the
pre-set date or total distance travelled. The
specialist dealer needs to connect the pedelec to
an E-TUBE PROJECT for this purpose.
Notice
Excessive chain tension increases wear.
If the chain tension is too low, there is a risk that
the chain or the drive belt will slip off the chain
wheels.
Check the chain tension once a month.
2 cm
1
MY20P03-22_1.0_18.07.2019 85
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.
Technical expertise, special tools and special
lubricants are required no matter whether disc
brakes need replacing, brakes venting or wheels
changing. 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 appendix.
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 1 mm 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.
Never carry out work or changes (such as
dismantling, sanding or painting) which are not
explicitly allowed and described in the brake user
manual.
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 to protect your eyes
when carrying out maintenance work such as
replacing components.
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
!
MY20P03-22_1.0_18.07.2019 86
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 Axle with quick release
8.1.1 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 79: Adjusting the quick release clamping force
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Afterwards, check the quick release lever
position and clamping force.
Figure 80: Adjusting the quick release clamping force
8.2 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.
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
!
MY20P03-22_1.0_18.07.2019 87
Maintenance
8.2.1 Cable-operated gear shift, single-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, adjust the adjusting
sleeves on the shifter housing.
Figure 81: Adjusting sleeve (1) for the single-cable, cable-
operated gear shift with shifter housing (2), example
8.2.2 Cable-operated gear shift, dual-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves underneath the chain stay on the
frame.
The shift cable has around 1 mm play when it
is pulled out gently.
Figure 82: Adjusting sleeves (2) on two alternative
versions (A and B) of a dual-cable, cable-operated gear
shift on the chain stay (1)
8.2.3 Cable-operated twist grip, dual-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves on the shifter housing.
There is noticeable play of around 2–5 mm (1/
2 gear) when twisting the twist grip.
Figure 83: Twist grip with adjusting sleeves (1) and play of
the gear shift (2)
2
2
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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 the corresponding error code will appear
on the display screen. Depending on the type of
error, the drive will also be automatically switched
off.
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:
Check whether the battery is switched on. If
not, start the battery.
Contact specialist dealer if the battery level
indicator LEDs do not light up.
If the LEDs on the battery level indicator light
up, but the drive system does not start up,
remove the battery.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the battery.
Clean all the contacts with a soft cloth.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the battery.
Fully charge the battery.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the display.
Fasten the display.
Start the drive system.
Contact your specialist dealer if the drive
system does not start up.
9.1.2 Error messages
If an error message is displayed, run through the
following actions:
Make a note of the system message.
Shut off and re-start the drive system.
If the system message is still displayed,
remove and then re-insert the battery.
Re-start the drive system.
If the system message is still displayed,
contact your specialist dealer.
Risk of fire and explosion due to faulty battery
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. Batteries may self-ignite and
explode.
Batteries with external damage must be
removed from service immediately.
Never allow damaged batteries to come into
contact with water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
WARNING
!
MY20P03-22_1.0_18.07.2019 89
Troubleshooting, fault clearance and repair
9.2 Assistance function
Symptom Cause Remedy
Assistance is not available.
Is the battery charged sufficiently? Check the battery level.
If the battery is almost flat, recharge it.
Are you riding on long inclines in summer
weather or have you been carrying a heavy
load for a long time?
The battery may be too hot.
Turn off the drive system.
Wait a while and then check again.
The drive unit (DU-E6100/DU-E6110), the
bicycle computer (SC-E6100) or the
assistance switch (SW-E6010/SW-E7000)
may be connected incorrectly or one or
more of them may have a problem.
Contact your specialist dealer.
Is the speed too high?
Check the on-screen indicators.
The electronic gear assistance only works up to a maximum speed
of 25 km/h.
Assistance is not available.
Are you pedalling? The pedelec is not a motorbike. You also need to pedal.
Is the assistance mode set to [OFF]?
Set the assistance mode to a different level of assistance than
[OFF].
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
Is the system switched on? Press the battery on-off button to switch it on again.
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.
Check the battery level.
If the battery is almost flat, recharge it.
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 the tyres.
Is the assistance mode set to OFF?
Select the level of assistance [BOOST].
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
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?
Switch the system on again without applying pressure to the pedal.
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
Table 51: Level of assistance error solution
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Troubleshooting, fault clearance and repair
9.3 Rechargeable battery
Symptom Cause Remedy
The battery discharges
quickly.
The battery may be at the end of its service
life.
Replace the battery with a new one.
All five battery indicators are
continuously lit.
The drive unit firmware version may not be
up to date.
Contact your specialist dealer.
The battery cannot be
recharged.
Is the charger mains plug firmly connected
to the socket?
Pull out the charger mains plug and reconnect it again.
Try charging again.
If the battery still won’t recharge, contact your specialist dealer.
Is the charger plug firmly inserted into the
battery?
Pull out the charger mains plug and reconnect it again.
Try charging again.
If 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?
Connect the adapter firmly to the charger plug or the battery’s
charging port.
Re-start the charging process.
Contact your specialist dealer if the battery still does not charge.
Is the battery, the connection terminal for
the battery charger or the charger adapter
dirty?
Wipe the connection terminal with a dry cloth to clean it.
Try charging again.
If the battery still won’t recharge, contact your specialist dealer.
The battery does not start
charging when the charger
is connected.
The battery may beat the end of its service
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.
Stop the charging process.
Wait a while and then start charging again.
If 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
inserted into the battery?
Check the connection to the external body before inserting the
charger plug again.
If 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.
Pull out the charger mains plug and reconnect it again.
Then try charging again.
If 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.
Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
There is an unusual smell.
Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
Table 52: Error solution for battery
WARNING
!
WARNING
!
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Troubleshooting, fault clearance and repair
9.4 Lighting
9.5 Display
Fumes are emitted from the
battery.
Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
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.
Take the pedelec out of service immediately.
Contact your specialist dealer.
Table 53: 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.
Charge the battery.
Switch 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 mount
correctly?
Check whether the power cable connector connecting the motor unit
to the drive unit has not 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.
The gear level is not shown
on the display.
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 malfuction.
Stop the pedelec and then adjust the settings.
Table 54: Error solution for the display
Symptom Cause Remedy
Table 52: Error solution for battery
WARNING
!
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Troubleshooting, fault clearance and repair
9.6 Miscellaneous
9.7 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 brake pads and brake linings
• Replacing and tensioning the chain.
9.7.1 Use original parts and lubricants
only
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 list are Section 11, Documents and
Drawings.
9.7.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.7.3 Setting the headlight
The headlight must be set, so that its light beam
shines on the road 10 m in front of the pedelec.
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.
You hear a noise after
shifting gears.
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
MY20P03-22_1.0_18.07.2019 93
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. Sorted waste collection and
recycling saves on raw material reserves and
ensures that all the regulations for health and
environmental protection are met when the
product and/or the battery are recycled.
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.
Risk of fire and explosion
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove battery with any external damage
from service immediately and never recharge
it.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish damaged batteries with
water or allow them to come into contact with
water.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly as quickly
as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Chemical burns to the skin and eyes
Liquids and vapours may leak from a damaged or
faulty battery. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
WARNING
!
CAUTION
!
Hazard for the environment
The fork, rear frame damper and hydraulic brake
system contain toxic and environmentally harmful
oils and lubricants. Such fluids will contaminate if
they enter the sewers or groundwater.
Dispose of lubricants and oils in an
environmentally responsible way in
accordance with statutory regulations.
CAUTION
!
MY20P03-22_1.0_18.07.2019 94
Documents
11 Documents
11.1 Parts list
There was no information relating to a parts list
yet at the time of going to press. You'll find the
information in the latest operating instructions.
MY20P03-22_1.0_18.07.2019 95
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 battery 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 battery if necessary
Reflectors All complete, state,
fastening O.K. Damaged or not all
complete
New reflectors
MY20P03-22_1.0_18.07.2019 96
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 display,
defective screen display
Restart, test battery, new
software, or new display; take out
of service,
Electric drive control
panel Check 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
Shut off pedelec until source of
fault 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
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
Components Description Criteria Measures if rejected
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Documents
11.3 Maintenance log
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
Shut off pedelec; new frame
Handles, cover-
ings
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 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
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Documents
Inspection Tests Maintenance Accept-
ance
Rejection
Light system
Rechargeable
battery
First examination O.K. Error message Contact battery
manufacturer; take out of
service, 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 New rear light as specified in
parts list; replace battery if
necessary
Front light
Side light, daytime
riding light
Functional check O.K. No constant light New front light as specified
in parts list; replace battery if
necessary
Reflectors All complete, state,
fastening
O.K. Damaged or not
all complete
New reflectors
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
display, defective
screen display
Restart, test battery, new
software, or new display;
take out of service,
Electric drive con-
trol panel
Check drive 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
Shut off pedelec until source
of fault 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; take out of service
Software Check version In latest
version
Not latest version Import update
Components Frequency Description Criteria Measures if rejected
MY20P03-22_1.0_18.07.2019 99
Documents
Technical inspection, checking safety, test ride
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 operat-
ing load
Functional check O.K. Problems when shifting
gear
Readjust gear shift
Suspension compo-
nents (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
MY20P03-22_1.0_18.07.2019 101
Keyword index
12 Keyword index
A
Air chamber, 18
Air valve
Fork, 17
Rear frame damper, 18
Alternative equipment, 7
B
Back-pedal brake,
-braking, 75
Battery level indicator, 27
Battery, 21
- charging, 64, 65
- checking, 35
- disposing of, 94
Belt tension, 85
Brake arm, 18
Brake calliper, 19
Brake disc, 19
Brake lever, 27
- adjusting the pressure point 47
Brake lining, 18, 19
- maintaining, 84
Brake,
- using the transport securing
system, 32
Break in operation, 33
- carrying out, 33
- preparing, 33
Button,
On-Off (display), 27
Riding light, 27
C
Chain drive, 20
Chain guard,
- checking, 60
Chain tension, 85
Chain wheel, 20
Chain, 15, 20
- maintaining, 85
Charger,
- disposing of, 94
Clamping force,
- Checking the quick releases, 37
- Setting the quick releases, 37
D
Direction of travel, 20
Display, 21
- charging the battery, 67
Drive system, 20
- switching off, 66
- switching on, 66, 67
F
Fork lock,
Position, 17
Fork, 16
Fork end, 16
structure, 17
Frame, 15
Front wheel brake, 18, 19
- braking, 74
Front wheel, see Wheel
G
Gear recommendation, 28, 29
Gear shift twist grip, 27
- checking, 84
Gear shift,
- maintaining, 84
- switching, 76
H
Handlebars, 15
Hub, 16
I
Initial commissioning 35
J
Journey information,
- switching, 28, 68
Maximum, 28, 68, 69
L
Level of assistance, 28, 30, 68
- selecting, 68
ECO, 28, 68
SPORT, 28, 68
TOUR, 28, 68
TURBO, 28, 68
Lever, 18
M
Minimum insertion depth marking, 45
Model year, 8
Mudguards,
- checking, 60
O
On-Off button,
Display, 27
On-screen indicator, 27, 59
Operating status indicator, 27
O-ring, 18
P
Packaging, 34
Pannier rack, 15
- changing, 61
- checking, 60
- using, 61
Pedal, 19, 20
Push assist,
- using, 67
Q
Quick release, 16
Position, 17
R
Rear frame damper,
structure, 18
Rear wheel brake, 19
Rebound damper adjuster,
Position, 17
Riding light button, 27
Riding light, 21
- checking function, 60
Rim brake locking lever 19
Rim, 16
- checking, 82
Roller brake,
-braking, 75
S
Saddle, 15
- changing the saddle tilt, 44
- changing the seat length, 45
- determining the saddle height, 44,
45
Seat post, 15
Setting wheel, 18
Shifter,
- checking, 84
- setting, 87
Spoke, 16
Storage, 32
Storing, see Storage
Suspension head, 16
System message, 29
System setting, 29
changeable, 29
T
Transportation, 31
Transporting, see Transportation
Type number, 8
Tyres, 16
- checking, 82
U
Using 76
V
Valve cap, 17
Valve, 16
Dunlop valve, 16
Presta valve, 16
Schrader valve, 16
W
Weight,
permitted total weight, 8
Wheel,
- maintaining, 82
Winter break, see Break in operation
MY20P03-22_1.0_18.07.2019 101
Glossary
13 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.
MY20P03-22_1.0_18.07.2019 102
Glossary
Maximum continuous power
Source: ZEG: the maximum continuous power is
the maximum power for the electric motor output
shaft during 30 minutes.
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.
MY20P03-22_1.0_18.07.2019 103
Glossary
Wear
Source: DIN 31051: reduction in useful life (4.3.4),
caused by chemical and/or physical processes.
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).
MY20P03-22_1.0_18.07.2019 105
Appendix
Appendix
I. Translation of the original EC declaration of conformity
The manufacturer:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
hereby declares that the electrically power assisted cycles of types:
20-17-3142, 20-17-3144, 20-17-3066, 20-17-3067, 20-17-3068, 20-17-3072, 20-17-3073, 20-17-3074,
20-17-3220, 20-17-3222
Year of manufacture 2019 and year of manufacture 2020
comply with all applicable requirements of Machinery Directive 2006/42/EC. Furthermore, the electrically
power assisted cycles comply with all applicable basic requirements of Electromagnetic Compatibility
Directive 2014/30/EU.
The following standards were applied: ISO/DIS 20607:2018 Safety of machinery – Instruction handbook –
General drafting principle; EN 15194:2018 Cycles – Electrically power assisted cycles – EPAC bicycles
and EN 11243:2016 Cycles – Luggage carriers for bicycles – Requirements and test methods.
Ms. Janine Otto (Technical Editor), c/o ZEG Zweirad-Einkaufs-Genossenschaft eG, Longericher Straße 2,
50739 Köln, Germany, is authorised to compile the technical documentation.
Cologne, 26/06/2019
…………………………………………………………………………………………………………………
Place, date and signature
Egbert Hageböck
-Chairman-
… 104


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