Bosch ZEMO ZE FS P12 Translation Of The Original Operating Instructions
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Bosch ZEMO ZE FS P12 Translation Of The Original Operating Instructions

Bosch ZEMO ZE FS P12 Translation Of The Original Operating Instructions

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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE
Translation of the original operating instructions
for ZEMO pedelecs with pinion motor and
FIT Comfort display
Z E F S P 1 2
Z A - 1 5 - 0 0 6 4
M Y 2 3 Z 1 2 - 1 2 _ 1 . 0 _ 2 6 . 0 1 . 2 0 2 4

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Summary of Contents for Bosch ZEMO ZE FS P12

  • Page 1 IMPORTANT READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of the original operating instructions for ZEMO pedelecs with pinion motor and FIT Comfort display Z E F S P 1 2 Z A - 1 5 - 0 0 6 4 M Y 2 3 Z 1 2 - 1 2 _ 1 .

  • Page 2: Table Of Contents

    Proper use 3.1.1 Pedelec type 3.1.2 Improper use 3.1.3 Area of use as per EN 17406, from model year 2024 Technical data 3.2.1 Complete BOSCH vehicle 3.2.2 Dimensions Nameplate 3.3.1 Model year 24 Components 3.4.1 Overview of city and trekking bicycle 3.4.2...
  • Page 3 Contents 3.5.1 Display 3.5.2 Handbrake 3.5.3 Gear shift 3.5.4 Suspension and damping 3.5.5 Indicators on the battery Transportation 3.6.1 Using the transport securing system 3.6.2 Transporting the pedelec 3.6.3 Shipping a pedelec 3.6.4 Transporting the battery 3.6.5 Shipping the battery Storing 3.7.1 Battery storage mode...
  • Page 4 Contents 6.5.1 Child seat 6.5.2 Trailer 6.5.3 Pannier rack 6.5.4 Panniers and cargo boxes 6.5.5 Front baskets 6.5.6 Bar ends 6.5.7 Kickstands 6.5.8 Additional battery headlight 6.5.9 Mobile holder 6.5.10 Suspension fork coil spring 6.5.11 Fixed weather protection systems Personal protective equipment and accessories for road safety Before each ride Using the battery 6.8.1...
  • Page 5 Contents 7.1.7 Check wheel concentricity 7.1.8 Checking the quick releases 7.1.9 Checking the suspension seat post 7.1.10 Checking the bell 7.1.11 Checking the handles 7.1.12 Checking the USB cover 7.1.13 Checking the riding light 7.1.14 Checking the brake After each ride 7.2.1 Cleaning the riding light and reflectors 7.2.2...
  • Page 6 Contents 7.5.3 Checking the belt 7.5.4 Checking the riding light 7.5.5 Checking the stem 7.5.6 Checking the handlebars 7.5.7 Checking the saddle 7.5.8 Checking the seat post 7.5.9 Checking the pedal 7.5.10 Checking the gear shift Inspection and maintenance Initial inspection Major inspection Component-specific maintenance Carrying out initial inspection...
  • Page 7 Contents Recycling and disposal 10.1 Guidelines on removal of waste Documents 11.1 Assembly report 11.2 Inspection and maintenance log Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Keyword index MY23Z12 - 12_1.0_26.01.2024...
  • Page 8 About these operating instructions Thank you for your trust! Copyright ZEMO pedelecs are premium quality bicycles. © ZEG Zweirad-Einkaufs-Genossenschaft eG You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product.

  • Page 9: About These Operating Instructions

    About these operating instructions About these operating instructions Manufacturer CAUTION ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Strasse 2 May lead to minor or moderate injuries if ignored. 50739 Köln Low-risk hazard. Germany Notice Tel.: +49 221 17959 0 Fax: +49 221 17959 31 May lead to material damage if ignored.

  • Page 10: Language

    About these operating instructions Language The original operating instructions are written in Section German. A translation is invalid without the original operating instructions. About these operating instructions   Aim of the operating instructions Safety   These operating instructions are an integral part Description ...

  • Page 11: Type Number And Model

    About these operating instructions Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part of stamped on it (see Figure 2). The frame number pedelecs with the type numbers: can be used to link the pedelec with the owner. Type no.

  • Page 12: Safety

    Safety Safety Residual risk Pedelecs pose the following residual risks: Never use incorrect charger • Risk of fire and explosion Chargers with excessive voltage damage • Electric shock batteries. This may cause a fire or an explosion. • Risk of a crash ...
  • Page 13 Safety Storing faulty batteries Your specialist dealer will dispose of faulty batteries.  Take faulty batteries to your specialist dealer.  Store the battery in a safety container in a dry place as per special regulations (ADR SV 376, P908) until you dispose of it. Figure 1: Example of a safety container ...

  • Page 14: Electric Shock

    Safety Use correct torque 2.1.2 Electric shock If a screw is fastened too tightly, it may break. If a screw is not fastened enough, it may loosen. This will cause a crash with injuries. Never use damaged network components  Always observe the indicated tightening torque Damaged chargers, cables and plug connectors on the screw or in Section 3.5.

  • Page 15: Toxic Substances

    Safety Toxic substances 2.2.2 Irritants and If substances are released or used which pose a corrosive risk to people and the environment, effective substances protective measures must be taken. Possible hazards, contamination and health Corrosive substances (also known as corrosives) hazards due to: destroy living tissue or attack surfaces.

  • Page 16: Personal Protective Equipment

    Safety Personal protective equipment Safety markings and safety instructions  Wear a suitable helmet. The helmet must have a reflective strip or a light in a clearly visible Pedelec and battery nameplates contain the colour. following safety markings and safety instructions: ...

  • Page 17: What To Do In An Emergency

    Safety What to do in an emergency After contact with eyes 1 Rinse eyes under flowing water for at least ten 2.8.1 Dangerous situation in road traffic minutes with the lids open; also rinse under lids.  If you encounter any hazards or dangers in road traffic, apply the brake on the pedelec 2 Immediately consult a doctor in case of any until it comes to a halt.

  • Page 18: Battery Vapour Emission

    Safety 2.8.3 Battery vapour emission 2.8.4 Battery fire Vapours may be emitted if the battery is damaged The safety electronics may fail if the battery is or used improperly. The vapours may cause damaged or faulty. The residual voltage can respiratory tract irritation.

  • Page 19: Description

    Description Description Proper use All checklists and instructions for actions in these reflectors and other components when riding on operating instructions met. Approved accessories public roads. The general laws and the can be installed by specialist staff. regulations for the prevention of accidents and environmental protection in the respective country Use the pedelec when it is in perfect, proper of use must be adhered to.

  • Page 20: Area Of Use As Per En 17406, From Model Year 2024

    Description 3.1.3 Area of use as per EN 17406, from model year 2024 Average Area of use Unsuitability speed [km/h] Use on normal, paved surfaces where the tyres should maintain 15 ... 25 • Never ride off road. contact with the ground at average speed with occasional jumps. •...

  • Page 21: Technical Data

    Description Technical data 3.2.1 Complete BOSCH vehicle 3.2.1.2 Environmental requirements You can be ride the pedelec within a temperature range between -5 °C and +40 °C. The electric Power output/system 250 W (0.25 kW) drive system is limited in its performance outside...

  • Page 22: Dimensions

    Description 3.2.2 Dimensions The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is • the weight of the fully assembled pedelec • plus body weight • plus baggage Type no. Model PTW [kg] Weight [kg] ZA-15-0064...

  • Page 23: Nameplate

    Description Nameplate 3.3.1 Model year 24 ZEG Zweirad-Einkaufs- Genossenschaft eG The nameplate is situated on the frame. The Longericher Str. 2 precise position of the nameplate is shown in 50739 Köln, Germany TYP: XX-XX-XXX Figure 3. EPAC nach The nameplate contains up to twelve pieces of EN 15194 information.

  • Page 24: Components

    Description Components 3.4.1 Overview of city and trekking bicycle 18 19 21 22 23 Figure 3: Pedelec viewed from the right, example Wheel Seat post Rear wheel brake Saddle Belt Suspension fork Pannier rack Rear frame damper Guard Rear light Crank Front light Guard...
  • Page 25 Description 3.4.1.1 Components and repair parts for ZE FS P12 ZA-15-0064 Diamant, Wave Shape: Diamant, frame size: 45 cm Shape: Diamant, frame size: 50 cm Shape: Diamant, frame size: 55 cm Frame ZEMO, ZE FS P12 Shape: Diamant, frame size: 60 cm Shape: Wave, frame size: 45 cm Shape: Wave, frame size: 50 cm Shape: Wave, frame size: 55 cm...
  • Page 26 Description # Belt, polyurethane/carbon; pitch: 11, number of GATES®, 125T CDX (11M-125T-12CT) teeth: 125; width: 12 mm; length: # mm Chain/belt # Belt, polyurethane/carbon; pitch: 11, number of GATES®, 128T CDX (11M-128T-12CT) teeth: 128; width: 12 mm; length: # mm GATES®, 39T Pinion # CDX (CDXFP139) Belt sprocket, 39T, for PINION Chain wheel/belt sprocket...

  • Page 27: Chassis

    Description 3.4.2 Chassis Carbon frame The chassis comprises two components: Carbon (CFRP) is a carbon-fibre-reinforced polymer made of high-strength, rigid fibres. • Frame and Carbon frames comprise several layers of carbon • steering system with an epoxy resin matrix. The uppermost layer is known as the visible layer.
  • Page 28 Description Rider’s height [cm] Frame size [cm] Rider’s height [cm] Frame size [cm] 155… 165 160… 175 43… 48 46… 48 165… 175 48… 53 165… 180 49… 51 175… 185 53… 58 170… 185 52… 54 185… 195 58… 62 175…...
  • Page 29 Description 3.4.2.2 Rear frame damper A rear frame damper is primarily fitted to mountain The rear frame damper rebounds at a controlled bikes and helps to protect the pedelec and rider speed if it is optimally adjusted. The rear wheel against impacts and vibrations caused by uneven does not bounce off rough surfaces or the ground;...
  • Page 30 Description When optimally adjusted, the rear frame damper The saddle rises slightly when absorbing a bump deflects quickly and unhindered when the bike hits (green line). bumps and absorbs a bump. Traction is retained (blue line). Figure 7: Optimum rear frame damper ride performance over bumps MY23Z12 - 12_1.0_26.01.2024...
  • Page 31 Description ROCKSHOX Deluxe Select+ structure design Figure 8: ROCKSHOX Deluxe Select rear frame damper structure design Air valve (rear frame damper) Rebound adjuster (rear frame damper) Compression lever (rear frame damper) O-ring Scale MY23Z12 - 12_1.0_26.01.2024...
  • Page 32 Description 3.4.2.3 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.4.2.4 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
  • Page 33 Description 3.4.2.6 Handlebars The pedelec is steered using the handlebars. The handlebars are used to support the upper body and are used to mount operating and display components (see Section 3.4.1). Figure 12: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
  • Page 34 Description Parts of a suspension fork Figure 13: Parts of a suspension fork Fork steerer Tyre clearance Sag adjuster Fork crown Tyre height Deflection (suspension fork) Tyre passage width Damper side Quick release Side view Pitch Installation height Fork end (suspension fork) Offset Quick release axle Air suspension side...
  • Page 35 Description Suspension fork assembly groups A suspension fork can feature up to three different assembly groups: • Compression damper (blue) • Rebound damper (red) • Air suspension or steel spring (orange) Figure 15: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
  • Page 36 Description Lock The compression can be disabled in any A suspension system absorbs great deal of motor suspension fork. A suspension fork will then and muscle power during rides uphill or on behave like a rigid fork. optimally tarmacked roads. This increases energy consumption and reduces propulsion.
  • Page 37 Description The suspension fork also deflect quickly and The suspension fork responds instantly to the unhindered when hitting bumps and cushions the impact. The headset and handlebars rise slightly bump when placed at an optimum setting. when absorbing a bump (green line). Traction is retained (blue line).
  • Page 38 Description Compression dampers When optimally adjusted, the suspension fork counteracts deflection on hilly terrain, stays Compression dampers damp deflection higher in its deflection range and helps to maintain movements, i.e. compression loads. speed when riding on hilly terrain. The compression damper controls the The suspension fork deflects instantly unhindered compression stroke speed or the extent to which and absorbs bumps when the bike hits one.
  • Page 39 Description Low-speed damper A slow compression speed is generated in the suspension fork when riding over bumps. The low- The low-speed damper (also abbreviated to LSC speed damper controls the suspension fork's from low-speed compression) is a specialised behaviour positively in such riding situations. compression damper.
  • Page 40 Description 3.4.2.8 SR SUNTOUR 2CR-PCS The Suntour 3CR-PCS cartridge features a PCS damper platform with • a low-speed compression damper • a rebound damper Floating pistons within the PCS cartridge provide consistent damping on all driving surfaces through minimal cavitation (formation and dissolution of bubbles by mixing air and oil).

  • Page 41: Wheel

    Description 3.4.3 Wheel Tyre pressure The permitted pressure range is indicated on the side of the tyre. It is indicated in psi or bars. The tyre is only able to support the pedelec if there is adequate tyre pressure. The tyre pressure must be adjusted to the body weight and then checked on a regular basis.
  • Page 42 Description Carcass Tread with profile The carcass is the tyre’s supporting structure. A rubber tread is attached to the exterior of the There are usually three carcass plies beneath the carcass. tread. The carcass comprises a webbing with The tread has little influence on riding characteristics threads, usually made of polyamide (nylon).
  • Page 43 Description Bead core 3.4.3.3 Rim The rim is the metal profile on a wheel which holds Tyre carcasses are wrapped around bead cores. the tyre, tube and rim band together. The rim is Wrapping the carcass around both sides creates joined to the hub with spokes.
  • Page 44 Description Presta valve 3.4.3.6 Spoke nipples The Presta valve, also known as the Sclaverand Spoke nipples are screw elements with an internal valve or the French valve, is the narrowest variant thread which fits onto the spoke thread. Fitted of all valves. The Presta valve requires a smaller spokes are tensioned by tightening the spoke hole in the rim, which is why it is especially nipples.
  • Page 45 Description 3.4.3.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.

  • Page 46: Brake

    Description 3.4.4 Brake 3.4.4.2 Hydraulic brake A pedelec’s brake system is primarily operated using the brake lever on the handlebars. The brake fluid is in a closed hose system. If the brake lever is pulled, the brake fluid transfers • If the left brake lever is pulled, the brake on the front wheel is applied.
  • Page 47 Description 3.4.4.3 Disc brake Figure 35: Brake system with disc brake – example Brake disc Brake calliper with brake linings Handlebars with brake lever Front wheel Brake disc Rear wheel brake disc On a pedelec with a disc brake, the brake disc is permanently screwed to the hub.

  • Page 48: Saddle

    Description 3.4.5 Saddle The purpose of the saddle is to absorb body When riding, the rider's body weight is distributed weight, provide support and enable different riding between the pedals, the saddle and the positions. The shape of the saddle thus depends handlebars.
  • Page 49 Description 3.4.5.1 Ladies’ saddle 3.4.5.2 Men’s saddle The distance between the ischial tuberosities and In contrast to the female anatomy, men's pubic the pubic symphysis is on average a quarter less bones are at a much steeper angle to one another. in women than in men.

  • Page 50: Seat Post

    Description 3.4.6 Seat post Seat posts are not designed to fasten the saddle but also to adjust exactly to the optimum sitting position. The seat post can: • adjust the seat height in the seat tube • adjust the saddle horizontally with a clamping mechanism and •...
  • Page 51 Description 3.4.6.3 Structure of LIMOTEC A3 dropper post The LIMOTEC Alpha 3 suspension seat post is a The suspension in the seat post ensures sitting continuously height-adjustable seat post, which comfort when riding over rough terrain (e.g. in can be lowered using a remote control on the woodland or on farm tracks).

  • Page 52: Mechanical Drive System

    Description 3.4.7 Mechanical drive system 3.4.7.1 Chain drive layout The pedelec is driven by muscle power, just like a bicycle. The force which is applied by pedalling in the direction of travel drives the front chain wheel. The chain or belt transmits the force onto the rear chain wheel and then onto the rear wheel.

  • Page 53: Pinion Electric Drive System

    Description 3.4.8 PINION electric drive system The pedelec has an electric drive system in The pedelec does not have a separate emergency addition to a mechanical one. shut-off button. In the event of an emergency, the motor can be stopped by removing the on-board computer.
  • Page 54 Description 3.4.8.5 FIT Remote Basic on-board computer The pedelec features a FIT Remote Basic on- Display board computer, which serves as a control panel. The on-board computer can be used with two The control panel on the handlebars uses 6 different displays.

  • Page 55: Handlebars With Fit Remote Basic With Fit Comfort Or Fit Compact Display

    Description 3.4.9 Handlebars with FIT Remote Basic with FIT Comfort or FIT Compact display Figure 51: Detailed view of handlebars with FIT Remote Basic on-board computer and Compact 2.0 display, as example Rear wheel hand brake (behind handlebars) FIT Remote Basic on-board computer Bell Air valve FIT Comfort 2.0 display...

  • Page 56: Control Panel

    Description 3.4.10 Control panel The on-board computer is operated using six buttons on the control panel. Figure 53: Overview of the BOSCH control panel On-Off button (control panel) Navigation rocker switch Plus key Minus key Push assist button Light button...

  • Page 57: Description Of Controls And Screens

    Description Description of controls and screens 3.5.1 Display 3.5.1.1 D RI V E MA IN ME NU The D RIV E MA IN ME N U screen will appear as soon as the display is switched on. The DRIVE M AIN M E NU has six indicator elements which are the same for all screens.
  • Page 58 Description 3. Guidance Bar indicator 8. Level of assistance indicator The higher the level of assistance, the more the drive system assists the rider when pedalling. The guidance bar will tell the rider which screen Level of assistance they are on. The screen that is open is highlighted. Maximum motor assistance.
  • Page 59 Description 3.5.1.2 DRIV E S UB -M E NU 3.5.1.3 T OU R MA IN ME N U The indicator elements in the DRI V E S U B - The indicator elements in the TO U R M A I N ME N U are the same as those in the DRIVE MAIN ME N U are the same as those in the DRIVE MAIN MENU.
  • Page 60 Description 3.5.1.4 T OU R S U B- ME NU 3.5.1.5 F ITN E S S M A IN ME N U The indicator elements in the TO U R SU B - The indicator elements in the FIT NES S MA IN ME N U are the same as those in the DRIVE MAIN ME N U are the same as those in the DRIVE MAIN MENU.
  • Page 61 Description 3.5.1.6 A RE A MA I N ME NU 3.5.1.7 S E TT INGS ME NU The indicator elements in the A REA M AIN All system and service-relevant values can be ME N U are the same as those in the DRIVE MAIN read and changed in the settings.
  • Page 62 Description – Resetting the values – Connectivity Reset values. → <Connect Komoot> → <Trip Reset> → <Connect Heart Rate Sensor> All values in the TOUR MAIN MENU and SUB-MENU are reset: – My Bike - Trip - Time - Trip Height →...
  • Page 63 Description – Charge This sets the desired charge mode. Selection Description Normal Normal charging Fast Fast charging Charge to Storage The battery is charged for a longer storage period LONG LIFE Less battery capacity is available but the battery life is considerably longer Table 96: Charge mode –...

  • Page 64: Handbrake

    Description 3.5.2 Handbrake There is a handbrake on the left and right of the handlebars. Figure 61: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example The left handbrake (2) controls the front wheel The right handbrake (1) controls the rear wheel brake.

  • Page 65: Gear Shift

    Description 3.5.3 Gear shift 3.5.3.1 Pinion, E-Trigger TE1 Only applies to vehicles with this equipment PRE.SELECT Figure 62: Parts of Pinion E-Trigger TE1 Ring clamp with screw PRE.SELECT can be activated by selecting the Connector <Shift> menu in the settings on the on-board Screw-on position with blind screw computer.

  • Page 66: Suspension And Damping

    Description 3.5.4 Suspension and damping 3.5.4.1 SR SUNTOUR air valve (fork) and sag setting wheel (fork) Model AIR EQ COIL Adjustable COIL Air valve (fork) Air valve (fork) Sag setting wheel Sag setting wheel Suspension Air suspension Air suspension Steel spring Steel spring Durolux Auron...
  • Page 67 Description 3.5.4.2 SR SUNTOUR adjuster damper Only applies to vehicles with this equipment R2C2-PCS 3CR-PCS 2CR-PCS RC-PCS Model RC2-PCS Suspension fork Aion Durolux Mobie34 Mobie35 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with high-speed and low-speed setting options and high-/low-speed compression damper in the R2C2-PCS piston compensator system Rebound damper with low-speed setting option and high-/low-speed compression damper in the piston...
  • Page 68 Description LORC-PCS Model LORC Suspension fork Aion Axon Mobie25 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with low-speed setting option and low-speed compression damper with lockout in the piston LORC-PCS compensator system LORC Rebound damper with low-speed setting option and low-speed compression damper with lockout Rebound damper with low-speed setting option with lockout MY23Z12 - 12_1.0_26.01.2024...
  • Page 69 Description 3.5.4.3 SR SUNTOUR adjuster damper with remote control Only applies to vehicles with this equipment There is a remote control to open and close the damper on the handlebars. R-3CR-PCS RLRC-PCS RLRC Model R-2CR-PCS Suspension fork Aion Axon Mobie25 Mobie34 Raidon Zeron35...

  • Page 70: Indicators On The Battery

    Description 3.5.5 Indicators on the battery The five LEDs on battery level indicator show the charge level when the battery is switched on. Each LED represents 20% of the battery level. 100 … 80% 79 … 60% 59 … 40% 39 …...

  • Page 71: Transportation

    Transporting and storing Transportation 3.6.2 Transporting the pedelec Lithium-ion batteries store great amounts of energy. You must comply with a few precautionary CAUTION measures when transporting gas cylinders.  Discharge the battery to about 30% before Crash caused by unintentional activation placing pedelec in a vehicle to transport or take There is a risk of injury if the electric drive system it on a trip.

  • Page 72: Shipping A Pedelec

    Transporting and storing 3.6.3 Shipping a pedelec 3.6.2.3 By local transport You can normally take pedelecs on local public  Private users are not permitted to ship transport, e.g. by bus or suburban rail, if you rechargeable batteries, neither by road not by purchase a bike ticket.

  • Page 73: Storing

    Transporting and storing Storing  Remove the on-board computer from its mount  Store pedelec, on-board computer, battery and if the pedelec is not going to be used for up to charger in a clean, dry place where they are four weeks.

  • Page 74: Assembly 5.1 Unpacking

    Assembly Assembly Scope of delivery WARNING 1 × pre-assembled pedelec  Risk of eye injury 1 × front wheel  Problems may arise if components are set 2 × pedals  incorrectly. They may cause serious injuries to 2 × quick releases (optional) ...

  • Page 75: Commissioning

    Assembly Commissioning Only trained specialist staff may perform initial commissioning since initial commissioning of the pedelec requires special tools and specialist knowledge. Experience has shown that a pedelec which has not yet been sold is automatically handed to customers as soon as it appears ready to ride. It makes sense to prepare each pedelec so that it is fully ready for use immediately after being assembled.

  • Page 76: Adjusting The Limotec Seat Post

    Assembly 5.3.2 Adjusting the LIMOTEC seat post Only applies to pedelecs with this equipment The rider’s body weight exceeds or falls below the  seat post’s functional weight. 1 Order new Limotec seat post with suitable functional weight. 2 Remove existing seat post. Replacing Limotec A1 and A5 3 Use the seat height formula to calculate the optimum seat post height for leg length:...

  • Page 77: Preparing The Wheel

    Assembly 5.3.3 Preparing the wheel There is an arrow on the sides of the tyres with the • The FRONT rotation direction arrow indicates the recommended direction of rotation for the front inscription ROTATION to show the direction of wheel. rotation.

  • Page 78: Installing The Wheel In The Suntour Fork

    Assembly 5.3.4 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.4.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this equipment Before installing the wheel, ensure that the O-ring 4 Insert the securing screw on the non-drive ...
  • Page 79 Assembly 5.3.4.2 20 mm cross axle Only applies to Suntour forks with this 2 Tighten the cross axle with the red handle. equipment CAUTION Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
  • Page 80 Assembly 5 Check the position and clamping force of the quick release lever. The quick release lever must be flush with the shock absorber. Figure 76: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
  • Page 81 Assembly 5.3.4.3 Q-LOC quick release Only applies to Suntour forks with this equipment 1 Push in the quick release until you can hear a click. Make sure that the flange is extended. CAUTION Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel.

  • Page 82: Checking The Stem And Handlebars

    Assembly 5.3.5 Checking the stem and handlebars 5.3.5.1 Checking the connections 5.3.5.3 Checking the bearing clearance 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.

  • Page 83: Assembly Instructions For Online Sales

    Assembly Assembly instructions for online sales 5.0.2 Preparing Your specialist dealer will complete assembly and commissioning for this pedelec. The pedals were unscrewed and the handlebars repositioned  Assemble the pedelec in a clean, dry environ- before transportation. You need these instructions ment.

  • Page 84: Straightening The Handlebars

    Assembly 5.0.4 Straightening the handlebars 5.0.4.2 Stem with clamping lever version II Only applies to pedelecs with this equipment The handlebars must be turned so that they are parallel to the frame and tyres for transportation. 1 Open the clamping lever on the stem quick 1 Turn handlebars clockwise until they are release.

  • Page 85: Checking The Stem And Handlebars Are In Correct Position

    Assembly 5.1.1 Checking the stem and handlebars are in correct position 5.1.1.1 Checking the connections 5.1.1.3 Checking the bearing clearance 1 Place the fingers of one hand on the upper 1 Stand in front of the pedelec. Clamp the front headset cup.

  • Page 86: Fitting The Pedals

    Assembly 5.1.2 Fitting the pedals 3 Turn the pedal marked R anti-clockwise by The pedals have two different threads to ensure they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.

  • Page 87: Operation

    Operation Operation Risks and hazards WARNING WARNING Injuries and death caused by distraction Injuries and death caused by blind spots A lack of concentration while riding increases the Other road users, trucks, cars and pedestrians risk of an accident. This may cause a crash with often underestimate the speed of pedelecs.
  • Page 88 Operation Notice CAUTION Heat or direct sunlight can cause the tyre pressure Crash caused by material fatigue to increase above the permitted maximum pres- Intensive use can cause material fatigue. A com- sure. This can destroy the tyres. ponent may suddenly fail in case of material ...

  • Page 89: Tips For A Greater Range

    Operation Tips for a greater range The pedelec’s range depends on many Gear switching habits influencing factors. A single battery charge may only last fewer than 20 kilometres but much more  Use a low gear and a low level of assistance on than 100 is also possible.

  • Page 90: Instruction And Customer Service

    Operation Instruction and customer service 6.4.1 Preparing The supplying specialist dealer will provide customer service. Contact details can be found on the pedelec pass for these operating instructions. The following tools are required to adjust the pedelec: The specialist dealer will explain all the pedelec functions to the new owner in person, this being when the specialist dealer hands over the pedelec Tape measure...

  • Page 91: Determining The Sitting Position

    Operation 6.4.2 Determining the sitting position The starting point for a comfortable posture is the Position on roadster Position on city bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.

  • Page 92: Seat Post

    Operation 6.4.3 Seat post 6.4.4 Saddle 6.4.3.1 Adjusting the seat post to body weight 6.4.4.1 Replacing the saddle Not included in price Not included in price Seat post are components that may be replaced Saddles are components that may be replaced §...
  • Page 93 Operation 6.4.4.2 Determining the saddle shape Ladies’ saddle To distribute the pressure optimally over the female bone structure in the seat area, a ladies’ saddle should: • have a relief opening far to the front • have a wide V-shaped saddle edge. Figure 89: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
  • Page 94 Operation 6.4.4.3 Determining the minimum saddle width With corrugated cardboard With a gel cushion 1 Place corrugated cardboard on a flat, hard, 1 Smooth gel cushion. unpadded seat. 2 Place gel cushion on a flat, hard, unpadded 2 Sit in the middle of the corrugated board. seat.
  • Page 95 Operation Using calculation Depending on the position, the following value is added to the minimum saddle width. Position on roadster + 4 cm Position on city bike + 3 cm Position on trekking bike + 2 cm Position on sports bike + 1 cm Triathlon/time trials + 0 cm...
  • Page 96 Operation 6.4.4.6 Straightening the saddle 4 Take a test ride.  Pedelec riders sit straight on the saddle at an  Position saddle in direction of travel. In doing optimal saddle height. so, align the tip of the saddle with the top tube. •...
  • Page 97 Operation 6.4.4.9 Adjusting the saddle position The saddle can be shifted on the saddle frame. The right horizontal position ensures an optimal leverage position for legs. This prevents knee pain and painful incorrect pelvis positions. If you have displaced the saddle more than 10 mm, you need to adjust the saddle height again since both settings affect one another.
  • Page 98 Operation 6.4.4.10 Adjusting the saddle tilt The saddle tilt must be adjusted to the seat height, the saddle and handlebar position, and the saddle shape to ensure an optimum fit. The seating position can be optimised in this way if needed. The saddle prevents pedelec riders from slipping backwards or forwards when placed in a horizontal position.

  • Page 99: Handlebars

    Operation 6.4.5 Handlebars 6.4.5.1 Replacing the handlebars 6.4.5.3 Adjusting the hand position The hand is an optimal position on the handlebars Not included in price when the forearm and hand are in a straight line, i.e. the wrist is not bent. In this way, the nerves are Handlebars are components that may be §...
  • Page 100 Operation 6.4.5.4 Adjusting the handlebars The handlebars and their position determine the posture that the pedelec rider adopts on the pedelec. 1 After selecting the seating position (see Section 6.5.2), determine the angle of the upper body and the upper arm. 2 Tension the back muscles when adjusting the handlebars.

  • Page 101: Stem

    Operation 6.4.6 Stem 6.4.6.1 Replacing the stem 2 Pull out the handlebars to the required height. Observe minimum insertion depth. Not included in price Handlebar-stem units are components that may § be replaced after approval by the vehicle or parts manufacturer.
  • Page 102 Operation 6.4.6.5 Setting the quill stem 6.4.6.6 Adjusting the Ahead stem Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment In the case of a quill stem, the stem and fork In the case of an Ahead stem, the stem is placed steerer form a permanently interconnected directly on the fork steerer, which protrudes over component, which is clamped in the fork steerer.

  • Page 103: Handles

    Operation 6.4.7 Handles 6.4.7.1 Replacing the handles 6.4.7.2 Adjusting ergonomic handles Only applies to pedelecs with this equipment Not included in price Handles with bolt clamps are components which § may be replaced without approval. Only handles that are approved for use on e-bikes may be used to replace the existing ones.

  • Page 104: Tyres

    Operation 6.4.8 Tyres 6.4.8.1 Replacing tyres As a general rule, wide tyres are operated at a lower tyre pressure. They provide the option of Not included in price exploiting the advantages of the lower tyre pressure without the serious disadvantages it Different tyres need to be used when the area of causes with regard to wear, rolling resistance and §...
  • Page 105 Operation 2 Perform a visual check on tyres. Figure 110: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 111: Far too little tyre pressure MY23Z12 - 12_1.0_26.01.2024...

  • Page 106: Brake

    Operation 6.4.9 Brake 6.4.9.3 Changing the handbrake position The handbrake grip distance can be adjusted to ensure that it can be reached more easily. The Having the handbrake in the correct position pressure point can also be adjusted to the pedelec prevents the rider from stretching their wrist too rider’s preferences.
  • Page 107 Operation 6.4.9.4 Changing the handbrake inclination 2 Set the brake lever angle as indicated in the angle table. The nerves that pass through the carpal tunnel are connected to the thumb and the index and middle fingers. An excessively steep or 20 –...
  • Page 108 Operation 6.4.9.6 MAGURA handbrake pressure point Only applies to pedelecs with this equipment The pressure point setting is adjusted using the twist knob. WARNING  Turn the twist knob towards the plus (+) Brake failure due to incorrect setting symbol. If the pressure point is set with brakes where the ...
  • Page 109 Operation 6.4.9.7 Setting the grip distance for a MAGURA handbrake disc brake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the rider’s requirements. Such adjustment does not WARNING affect the pressure point or the position of the Crash caused by incorrectly set grip distance brake linings.

  • Page 110: Control Panel And Gear Shift

    Operation 6.4.10 Control panel and gear shift The control panel and gear shift must be adjusted to the rider's needs. 1 Undo attachment screw. 2 Place control panel or gear shift into the position where the rider can use the control panel or the shifter with their thumb and/or index finger.

  • Page 111: Suspension And Damping

    Operation 6.4.11 Suspension and damping Suspension and damping can be adjusted to the  Follow the correct order for adjustment. rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Sequence Adjustment Section Suspension fork Rear frame damper...
  • Page 112 Operation 6.4.12.1 Adjusting the sag for the SR SUNTOUR steel suspension fork Only applies to pedelecs with this equipment You can pre-tension the steel suspension to riding style. It is not the coil spring hardness which adjust to the rider's weight and their preferred is adjusted;...

  • Page 113: Adjusting The Rear Frame Damper Sag

    Operation 6.4.13 Adjusting the rear frame damper sag Negative deflection (sag) CAUTION The sag is the percentage of total spring deflec- tion that is compressed by the rider’s body weight, Crash caused by broken rear frame damper including equipment (such as a backpack), their If the rear frame damper's maximum air pressure seating position and frame geometry.
  • Page 114 Operation 6.4.13.1 Adjusting the RockShox rear frame damper sag Only applies to pedelecs with this equipment Adjusting the suspension fork sag (see  Weight Air pressure Section 6.4.12). Pound per When adjusting the sag, ensure that all dampers  Kilogram Pound (lbs) square inch are in the open position, i.e.
  • Page 115 Operation 11 Read the sag value on the scale. The optimum sag percentage is 25%. The sag level may be adjusted by ± 5%, depending on the rider's preferences (20% to 30%). 12 The air pressure must be adjusted if the sag level is not reached.

  • Page 116: Adjusting The Suspension Fork Rebound Damper

    Operation 6.4.14 Adjusting the suspension fork rebound damper Only applies to pedelecs with this equipment Rebound damping is adjusted to the rider’s body weight, spring stiffness, deflection, the terrain and the pedelec rider's preferences. If the air pressure or spring stiffness increases, the extension and rebound speeds also increase.
  • Page 117 Operation 6.4.14.1 Adjusting the SR Suntour rebound damper suspension fork Only applies to pedelecs with this equipment Figure 123: Example of SR SUNTOUR rebound adjuster (suspension fork) (1) Adjusting the suspension fork sag (see  Section 6.4.12). 1 Turn the rebound adjuster (suspension fork) clockwise to the closed position until it stops.

  • Page 118: Adjusting The Rear Frame Damper Rebound Damper

    Operation 6.4.15 Adjusting the rear frame damper rebound damper Only applies to pedelecs with this equipment Adjust the rebound damper so that the rear frame damper rebounds quickly but without bottoming out upwards. Bottoming out refers to occasions when the rear frame damper rebounds too quickly and stops moving abruptly once it has reached the full rebound distance.
  • Page 119 Operation 6.4.15.1 Adjusting the ROCKSHOX rear frame damper rebound damper Only applies to pedelecs with this equipment Figure 124: The position and shape of the rebound adjuster (rear frame damper) depends on the model. Rebound adjusters are always red Adjusting the rear frame damper sag (see ...

  • Page 120: Riding Light

    Operation 6.4.16 Riding light 6.4.16.1 Replacing the headlight 6.4.16.2 Replacing the rear light and (spoke) reflector Not included in price Not included in price Headlights may only be replaced after approval § The rear light and (spoke) reflector may be §...
  • Page 121 Operation 6.4.16.4 Adjusting the headlight 1 Position the pedelec so that its front is facing a wall. 2 Mark the height of the headlight (1) on the wall with chalk. 3 Mark half the height of the headlight (2) on the wall with chalk.

  • Page 122: Adjusting The On-Board Computer And Fit Compact

    Operation 6.4.17 Adjusting the on-board computer and FIT Compact 6.4.17.2 Securing the display CAUTION It is possible to secure the display in its mount so that it cannot be removed. Crash caused by distraction A lack of concentration while riding increases the risk of an accident.
  • Page 123 Operation 6.4.17.4 Operating the display 6.4.17.6 Opening other menus The display is operated using six buttons on the  Press the navigations button to the left or control panel. right.  A new menu is displayed. 6.4.17.7 Changing the settings The pedelec is stationary.
  • Page 124 Operation Adjusting units Menu Submenu The displayed units can be shown using the metric → <Charge to Storage> or imperial system. The unit can be selected from → <LONG-LIFE mode> the following variables: Errors Variable Metric Imperial About Distance Table 110: Basic structure of FIT menu and sub-menu Speed km/h Setting the language...
  • Page 125 Operation Connecting the Komoot app Calibrating the altimeter The Komoot app can be connected to the FIT The altimeter can be calibrated. system. More information at: www.komoot.com/ 1 Open the S E TT INGS ME NU. 1 Open the S E TT INGS ME NU. 2 Open <My Bike><Calibration Altitude>.
  • Page 126 Operation Setting the vibration feedback Resetting all tour data The vibration feedback can be adjusted. All values in the TOUR MAIN MENU and SUB- MENU can be reset. 1 Open the S E TT INGS ME NU. • Trip 2 Open <My Bike><Vibration feedback>. •...

  • Page 127: Accessories

    Operation Accessories Notice Not included in price  Observe the legal regulations on the use of child seats. 6.5.1 Child seat  Observe the operating and safety instructions Child seats may only be used with the vehicle for the child seat system. §...

  • Page 128: Trailer

    Operation 6.5.2 Trailer 6.5.2.1 Approval for trailer with Enviolo hub Trailers may only be used with the vehicle Only applies to pedelecs with this equipment § manufacturer’s approval and only if they are approved for use on e-bikes. Only compatible bicycle trailers are approved for ENVIOLO hub gears.

  • Page 129: Pannier Rack

    Operation 6.5.2.2 Approval for trailer with ROHLOFF hub 6.5.3 Pannier rack Only applies to pedelecs with this equipment Front and rear pannier racks are only permitted § with the vehicle manufacturer’s approval and ROHLOFF Speedhub 500/14 only if they are approved for use on e-bikes. As a basic rule, it is permitted to use a trailer The specialist dealer will advise on choosing a in combination with the ROHLOFF...

  • Page 130: Front Baskets

    Operation 6.5.10 Suspension fork coil spring 6.5.5 Front baskets If the desired suspension fork sag cannot be Take care with front baskets because their load § achieved after adjustment, the coil spring distribution is not fixed. They are only permitted assembly must be replaced with a softer or harder with the vehicle manufacturer’s approval and spring.

  • Page 131: Personal Protective Equipment And Accessories For Road Safety

    Operation Personal protective equipment and accessories for road safety Seeing and being seen is crucial in road traffic. 7 The two separate brakes on the pedelec must The following requirements must be met for riding work at all times. a pedelec safely on public roads. 8 The clear sounding bell must be fitted and must work.

  • Page 132: Using The Battery

    Operation Using the battery Switch off the battery and the drive system before removing or inserting the battery.  6.8.1 Removing the battery 6.8.2 Inserting the battery 1 Turn locking lever to right. 1 Place the battery into the lower mount with the contacts facing the front.

  • Page 133: Charging The Battery

    Operation 6.8.3 Charging the battery The indicator shows the charge level during charging. CAUTION LED 1,2,3,4,5 Battery level Fire caused by overheated charger 100 - 80% The charger heats up when charging the battery. In case of insufficient cooling, this can result in 79 - 60% fire or burns to the hands.

  • Page 134: Straightening The Quickly Adjustable Stem

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

  • Page 135: Raising The Kickstand

    Operation 6.12.1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the leather to dry out and fade.  Park pedelec in the shade.  Always use a saddle cover. Moisture may cause the leather to detach from material beneath and mould may form.

  • Page 136: Setting The Saddle Height With The Remote Control

    Operation 6.14 Setting the saddle height with the 6.16 Using the handlebars remote control  Wear heavily padded cycling gloves. Only applies to pedelecs with this equipment  This helps protect sensitive areas of your palms. 6.14.1 Lowering the saddle ...

  • Page 137: Using Bar Ends

    Operation 6.16.2 Using bar ends Only applies to pedelecs with this equipment Bar ends can be added to normal handlebars. Adjustable bar ends feature a ball joint which you can use to choose the optimum position as required.  Adjust bar ends correctly. To do so, your hand, elbow and shoulder must be in line with one another when the hand takes hold of the bar ends.

  • Page 138: Adjusting The Rear Frame Damper

    Operation 6.16.4 Adjusting the rear frame damper  Before each ride, adjust the suspension and/or damping to the terrain if you have a rear frame damper. Terrain Position Suspension Setting off Open Uphill or tarmacked roads Lock out Energy saved while riding on roads and/or for Threshold maximum pedalling efficiency on flat or smooth terrain...
  • Page 139 Operation 6.16.4.2 Locking out the ROCKSHOX rear frame 6.16.4.4 Adjusting the ROCKSHOX rear frame damper damper threshold Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment Adjusting the rear frame damper rebound damper The pedelec's sag is configured. ...

  • Page 140: Adjusting The Rear Frame Damper Compression Damper

    Operation 6.16.5 Adjusting the rear frame damper compression damper When optimally adjusted, the rear frame damper The saddle rises slightly when absorbing a bump deflects quickly and unhindered when the bike hits (green line). bumps and absorbs a bump. Traction is retained The compression damper has two settings: (blue line).

  • Page 141: Electric Drive System

    Operation 6.17 Electric drive system 6.17.1 Switching on the electric drive 6.17.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in normal mode or reaches a speed of 25 km/h, the CAUTION drive system switches off the assistance system.

  • Page 142: Control Panel

    Operation 6.18 Control panel 6.18.1 Using the push assist system 3 Release the push assist button to switch off the push assist system. 4 Push assist mode switches off if the push CAUTION assist button is released for ten seconds. Push assist mode will also switch off Injury from pedals or wheels automatically if the speed exceeds 6 km/h.

  • Page 143: Selecting The Level Of Assistance

    Operation 6.18.2 Selecting the level of assistance  The control panel is used to set how much the electric drive assists the rider when pedalling. You can change the level of assistance at any time, even when you are cycling. Figure 152: Position of plus button (1), minus button (2) and push assist button (3) ...

  • Page 144: Using The Brake

    Operation 6.19 Using the brake 6.19.1 Using the handbrake Only applies to pedelecs with this equipment WARNING Crash caused by brake failure Oil or lubricant on the brake disc in a disc brake or on the rim of a rim brake can cause the brake to fail completely.

  • Page 145: Using Pinion Gears

    Operation 6.19.3 Using Pinion gears Only applies to pedelecs with this equipment Pinion gears switch between 9 or 12 speeds. It is 6.19.3.1 Shifting gear with E-Trigger TE1 possible to switch between several gears in one shift action (e.g. from 06 to 02). Changing gear is possible when the crank is stationary or rotating backwards and is gentle on the gears.

  • Page 146: Use Suspension And Damping

    Operation 6.20 Use suspension and damping 6.20.1 Locking the suspension A suspension system is designed to cushion and Some suspension forks thus feature a lockout on compensate for unevenness on a surface whether the crown or a remote lockout activated on the the user is riding on bumpy cycle paths, dirt roads handlebars.

  • Page 147: Adjusting The Suspension Fork Compression Damper

    Operation 6.20.2 Adjusting the suspension fork compression damper The compression damper allows the rider to make When placed at an optimum setting, the quick adjustments to the suspension behaviour of suspension fork counteracts deflection on hilly the suspension fork to adapt to changes in terrain. terrain, remains higher in its deflection range and It is intended for adjustments made during the helps maintain speed when riding on terrain hilly...
  • Page 148 Operation 6.20.2.1 Using SR Suntour high-speed compression damping A high speed is generated in the suspension fork, The settings on the high-speed damper control e.g. on a mogul slope or during landing after a the suspension behaviour of the fork during jump.
  • Page 149 Operation 6.20.2.2 Using the SR Suntour low-speed compression damping Low-speed movement in the suspension fork is The settings on the high-speed damper control caused, for example, by riding over bumps. the suspension behaviour of the fork • during staggered jumps •...

  • Page 150: Parking

    Operation 6.21 Parking 6 Remove battery to protect against theft (see Notice Section 6.16.1.1). 7 Clean and service pedelec after every ride; see Heat or direct sunlight can cause the tyre pressure Section 7.2. to increase above the permitted maximum pressure.

  • Page 151: Screwing In The Quickly Adjustable Stem

    Operation 6.21.1 Screwing in the quickly adjustable 6.21.2 Folding up the pedal stem  Clean the pedal (see Section 7.2.4). Only applies to pedelecs with this equipment 1 Use two fingers to pull the pedal folding latch (1) Screw in the quickly adjustable stem to save downwards and hold in position.

  • Page 152: Cleaning, Maintenance And Inspection

    Cleaning, maintenance and inspection Cleaning, maintenance and inspection  Clean, maintain and inspect pedelec as indicated on checklists. Complying with these cleaning instructions can increase operational reliability, reduce wear on components, extend the service life of components and ensure safety. Checklist: Before each ride Checklist: weekly tasks Check everything is sufficiently...
  • Page 153 Cleaning, maintenance and inspection Checklist: monthly tasks Checklist: monthly tasks Cleaning the battery See Section 7.3.2 Cleaning the motor See Section 7.3.3    Clean on-board computer See Section 7.3.1  Clean hub See Section 7.3.12  Clean on-board computer See Section 7.3.1 ...
  • Page 154 Cleaning, maintenance and inspection Checklist: Tasks performed at least every six months Checklist: Tasks performed at least every six months (or every 1,000 km) (or every 1,000 km) Check Bowden cables gear Servicing the stem See Section 7.4.6   See Section 7.5.10.2 shift...
  • Page 155 Cleaning, maintenance and inspection CAUTION WARNING Crash and falling caused by unintentional Crash caused by brake failure activation Oil or lubricant on the brake disc in a disc brake There is a risk of injury if the electric drive system or on the rim of a rim brake can cause the brake is activated unintentionally.

  • Page 156: Before Each Ride

    Cleaning, maintenance and inspection Before each ride 7.1.5 Checking the pannier rack Complying with these cleaning instructions is the only way to reduce wear on components, increase 1 Hold onto pedelec by its frame. Hold onto the operating hours and guarantee safety. pannier rack with the other hand.

  • Page 157: Checking The Suspension Seat Post

    Cleaning, maintenance and inspection 7.1.9 Checking the suspension seat post  Deflect and let the suspension seat post rebound.  If you hear unusual noises when the suspension seat post deflects and rebounds, or it yields without any resistance, take pedelec out of service.

  • Page 158: After Each Ride

    Cleaning, maintenance and inspection After each ride 7.2.4 Cleaning the pedals Complying with these cleaning instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. The following items should be ready for use to clean the pedelec after each ride: ...

  • Page 159: Basic Cleaning

    Cleaning, maintenance and inspection Basic cleaning 7.3.2 Cleaning the battery Complying with these basic cleaning instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. The following are required for basic cleaning: CAUTION Tool Cleaning agent Risk of fire and explosion due to penetration by...

  • Page 160: Cleaning The Frame, Fork, Pannier Rack, Guards And Kickstand

    Cleaning, maintenance and inspection 7.3.4 Cleaning the frame, fork, pannier 7.3.7 Cleaning the handles rack, guards and kickstand 1 Clean handles with sponge, water and soapy water. 1 Soak the components with dish-washing 2 Rinse off component with water from a detergent if the dirt is thick and ingrained.

  • Page 161: Cleaning The Saddle

    Cleaning, maintenance and inspection 7.3.9 Cleaning the saddle 7.3.12 Cleaning the hub 1 Clean the saddle with lukewarm water and a 1 Put on protective gloves. cloth dampened with soapy water. 2 Remove dirt from hub with a sponge and soapy 2 Rinse off component with water from a water.

  • Page 162: Cleaning The Cassette, Chain Wheels And Front Derailleur

    Cleaning, maintenance and inspection 7.3.16 Cleaning the brake 7.3.14.1 Cleaning the shifter 7.3.16.1 Cleaning the handbrake  Carefully clean shifter with a damp, soft cloth.  Carefully clean the handbrake with a damp, 7.3.15 Cleaning the cassette, chain wheels soft cloth. and front derailleur 7.3.17 Cleaning the brake disc...

  • Page 163: Cleaning The Chain

    Cleaning, maintenance and inspection 7.3.19 Cleaning the chain Notice  Never use aggressive (acid-based) cleaners, rust removers or degreasers when cleaning the chain.  Never use gun oil or rust remover spray.  Never use chain cleaning devices or chain cleaning baths.

  • Page 164: Maintenance

    Cleaning, maintenance and inspection Maintenance 7.4.1 Maintain frame Complying with these servicing instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Notice  Hard wax polish and protection wax are particularly resistant on gloss paintwork. These car accessory retail products are unsuitable for matt paint finishes.

  • Page 165: Maintain Pannier Rack

    Cleaning, maintenance and inspection 7.4.3 Maintain pannier rack 7.4.6 Maintaining the stem 1 Dry pannier rack with a cloth. 1 Spray painted and polished metal surfaces 2 Spray pannier rack with spray wax and leave to with wax spray and leave to dry. dry.

  • Page 166: Maintaining The Handles

    Cleaning, maintenance and inspection 7.4.8 Maintaining the handles Maintaining the 7.4.9.2 carbon seat post Maintaining 7.4.8.1 rubber handles 1 Apply talcum powder to sticky rubber handles. Notice Notice Rain and puddle water can cause contact  Never apply talcum powder to leather or foam corrosion if carbon seat posts are used in an handles.

  • Page 167: Maintaining The Hub

    Cleaning, maintenance and inspection 7.4.12 Maintaining the hub 7.4.14 Maintaining the gear shift Maintaining 7.4.14.1 the rear derailleur articu- lated shafts and jockey wheel 1 Apply wax spray especially around the spoke holes. In doing so, ensure that no wax is applied to brake parts.

  • Page 168: Maintaining The Chain

    Cleaning, maintenance and inspection 7.4.16 Maintaining the chain 7.4.16.1 Maintaining the chain and all-round chain guard Place newspaper or paper towels underneath to  Place newspaper or paper towels underneath to  collect chain oil. collect chain oil. 1 Lift rear wheel. 1 Lift rear wheel.

  • Page 169: Maintaining The Brake

    Cleaning, maintenance and inspection 7.4.18 Maintaining the brake 7.4.18.1 Maintaining the handbrake Notice  Never treat brake handbrake with degreaser or penetrating oil spray.  Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision mechanics oil.

  • Page 170: Inspection

    Cleaning, maintenance and inspection Inspection The following tools are required for an inspection: 7.5.1.1 Checking tyre pressure Notice Gloves If the tyre pressure is too low in the tyre, the tyre does not achieve its load bearing capacity. The Ring spanners 8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm tyre is not stable and may come off the rim.
  • Page 171 Cleaning, maintenance and inspection Dunlop valve Schrader valve Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment The tyre pressure cannot be measured on the It is recommended to use an air pump at a filling ...
  • Page 172 Cleaning, maintenance and inspection 7.5.1.2 Checking the tyres 2 Check the side walls for wear. If there are any cracks or tears, the tyre must be replaced. The tread is far less important for bicycle tyres than it is for car tyres, for example. Consequently, tyres can still be used with a worn tread with the exception of tyres on mountain bikes.
  • Page 173 Cleaning, maintenance and inspection 7.5.1.3 Checking the rims 7.5.1.5 Checking the nipple well The nipple holes can weaken the tyre bed. WARNING  Check to see if cracks are emerging from the nipple holes. Crash caused by a worn rim ...

  • Page 174: Checking The Brake System

    Cleaning, maintenance and inspection 7.5.2 Checking the brake system 7.5.2.2 Checking the hydraulic brake system CAUTION 1 Pull on the handbrake and check whether any brake fluid leaks out of the lines, connections or on the brake linings. Crash caused by brake failure Worn brake discs and brake linings and a lack of 2 If any brake fluid leaks from anywhere, take hydraulic fluid in the brake cable reduce the...
  • Page 175 Cleaning, maintenance and inspection 7.5.2.4 Checking the disc brake Only applies to pedelecs with this equipment Checking the brake linings Checking the brake discs  Check that the brake linings are no less than Put on gloves as the brake disc is very sharp. ...

  • Page 176: Checking The Belt

    Cleaning, maintenance and inspection 7.5.3 Checking the belt  The tooth profile is pointed and teeth have worn thinner. Contact specialist dealer. The belt sprocket does need to be replaced. 7.5.3.1 Checking the belt for wear  Check belt for indications of wear: Figure 169: Indications of wear on a belt Figure 171: Worn tooth profile 1 Carbon tensile fibres are exposed...
  • Page 177 Cleaning, maintenance and inspection There are three common methods of measuring 1 Open app. belt tension: 2 Click on the voltage symbol. • Gates Carbon Drive mobile app for iPhone® and 3 Click on MEASURE. Android®, • Gates Krikit tension meter and 4 Point phone microphone towards the belt.
  • Page 178 Cleaning, maintenance and inspection 3 Press the check gauge down with just one ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 175: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.

  • Page 179: Checking The Riding Light

    Cleaning, maintenance and inspection 7.5.4 Checking the riding light 1 Check the cable connections on the headlight  If the headlight or rear lights do not come on, take pedelec out of service. Contact specialist and rear light for damage and corrosion and dealer.

  • Page 180: Checking The Stem

    Cleaning, maintenance and inspection 7.5.5 Checking the stem 7.5.8 Checking the seat post 1 Take seat post out of the frame.  The stem and quick release system must be 2 Check seat post for cracks and corrosion. inspected at regular intervals. The specialist dealer should adjust them if they require 3 Reinsert seat post.

  • Page 181: Checking The Gear Shift

    Cleaning, maintenance and inspection 7.5.10 Checking the gear shift 4 Check that there is clearance between the chain tensioner and spokes. 1 Check that all gear shift components are free of  If there is no clearance or the chain scrapes damage.
  • Page 182 Cleaning, maintenance and inspection 7.5.10.5 Adjusting the ROHLOFF hub 7.5.10.6 Adjusting the cable-operated gear shift, dual-cable Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment 1 Check whether shift cable tension is set in such ...
  • Page 183 Cleaning, maintenance and inspection 7.5.10.8 Checking kickstand stability 1 Place the pedelec on a slight elevation of 5 cm. 2 Extend kickstand. 3 Jolt pedelec to check stability.  If pedelec topples over, tighten screws or change height of the kickstand. MY23Z12 - 12_1.0_26.01.2024...

  • Page 184: Inspection And Maintenance

    Inspection and maintenance Inspection and maintenance Initial inspection Component-specific maintenance After 200 km or 4 weeks after purchase High-quality components require extra maintenance. The tasks require technical Vibrations produced while riding can cause expertise, special tools and special lubricants. screws and springs that were tightened during The pedelec may become damaged if the pedelec manufacture to settle or come loose.
  • Page 185 Inspection and maintenance Inspection and maintenance intervals for suspension fork Inspection and maintenance intervals for seat post SR SUNTOUR suspension fork by,schulz suspension seat post Maintenance 1 Every 50 hours Maintenance After the first  250 km; every  1500 km after Maintenance 2 Every 100 hours ...
  • Page 186 Inspection and maintenance Inspection and maintenance intervals for rear frame Inspection and maintenance intervals for hub damper SHIMANO 11-speed hub RockShox rear frame damper Internal oil change and maintenance 1,000 km after Service air chamber assembly Every 50 hours start of use, then ...

  • Page 187: Carrying Out Initial Inspection

    Inspection and maintenance CAUTION WARNING Hazard for the environment due to toxic Injury due to damaged brakes substances Special tools and specialist knowledge are The brake system contains toxic and required to repair the brakes. Incorrect or environmentally harmful oils and lubricants. Such unauthorised assembly can damage the brakes.

  • Page 188: Perform Major Inspection

    Inspection and maintenance Perform major inspection Complying with these inspection and maintenance instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Diagnosis and documentation of current status Fre- Components Description Criteria Measures if rejected quency Accept- Inspection...
  • Page 189 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.5 O.K. Dirt Cleaning month 6 months … Section 7.4.6 O.K. Untreated Stem 6 months Check mount fas- Section 7.5.5 …...
  • Page 190 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Wheel Before Concentricity Section 7.1.7 … O.K. Not straight Re-mount wheel each ride Wheel 6 months Assembly Section 7.5.1 … O.K. Loose Adjust quick release Once a Cleaning Section...
  • Page 191 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.12 O.K. Dirt Cleaning month Once a Care … Section 7.4.12 O.K. Untreated Treat month Hub gear 6 months Check mount fas- …...
  • Page 192 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 20 hours Refill oil … Section 7.4.19 O.K. No oil Refill oil 20 hours Clean wiper O.K. Dirt Cleaning EIGHTPINS 40 hours Clean slide bushing O.K.
  • Page 193 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Back-pedal 6 months Attachment Check mount … O.K. Loose Retighten screws brake braking fastening armature 6 months Attachment Check mount … O.K. Loose Retighten screws Brake system fastening...
  • Page 194 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months First examination See Section on … O.K. Error message Contact battery manu- Rechargeable Assembly facturer; take out of battery service, new battery 6 months Firmly in position, Check mount...

  • Page 195: Inspect Frame

    Inspection and maintenance 8.5.1 Inspect frame 8.5.3 Inspecting and maintaining the rear frame damper 1 Check frame for cracks, warping and damage Only applies to pedelecs with this equipment to the paintwork.  If there are any cracks, warping or damage to the paintwork, remove the pedelec from WARNING service.

  • Page 196: Inspecting The Gear Hub

    Inspection and maintenance 8.5.5 Inspecting the stem CAUTION Incorrectly fastened screws may come loose due to impact. The stem may no longer be firmly fixed Hazard for the environment due to toxic in its position as a result. This will cause a crash substances with injuries.

  • Page 197: Inspecting The Axle With Quick Release

    Inspection and maintenance 8.5.7 Inspecting the axle with quick  The quick release lever is flush with the lower release housing.  You should be able to see slight impression on the palm of your hand when you close the quick CAUTION release lever.

  • Page 198: Inspecting The Fork

    Inspection and maintenance 8.5.8 Inspecting the fork 8.5.8.1 Inspecting the carbon suspension fork Only applies to pedelecs with this equipment WARNING 1 Remove fork. 2 Check fork for cracks, warping and damage to Injury due to explosion the paintwork. The air chamber is pressurised. When the air 3 You need to distinguish between scratches on system in a faulty suspension fork is maintained, the paintwork and impacts if the carbon...

  • Page 199: Inspecting The Seat Post

    Inspection and maintenance 8.5.9 Inspecting the seat post 8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post Only applies to pedelecs with this equipment WARNING 1 Remove seat post from the frame. Intoxication from lubrication oil 2 Remove safety and protective cover. The lubrication oil for Eightpins seat posts is toxic 3 Clean seat post on the inside and outside.
  • Page 200 Inspection and maintenance 8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post Only applies to pedelecs with this equipment 1 Remove seat post from the frame. 2 Remove safety and protective cover. 3 Examine seat post rack for scratches, cracks and fractures.

  • Page 201: Torque

    Mounting bracket 0.8 Nm Torx® T20 FIT Remote Display Mounting bracket 0.8 Nm Torx® T20 BOSCH Intuvia 100 bracket Attachment screw 1, M3 × 22 1 Nm 3 mm hex bit Attachment screw 2, M3× 14 1 Nm 3 mm hex bit...
  • Page 202 Description BOSCH Mini Remote Attachment screw 0.4 Nm (not 0.6 Nm, as written on mini-remote) 3 mm hex bit SHIMANO SC-E5003 0.8 Nm 3 mm hex bit Attachment screw Brake linings SHIMANO Hex key, 3 mm Circlip 2 … 4 Nm...
  • Page 203 Description SHIMANO for 5-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] SHIMANO for 6-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] TEKTRO for hydraulic disc brake system Attachment screws 4 … 6 Nm Torx®...
  • Page 204 Description SR SUNTOUR Damping side, top, aluminium 20 Nm SR SUNTOUR Damping side, bottom, without adjuster 10 Nm SR SUNTOUR Damping side, bottom, with adjuster 7 Nm SR SUNTOUR Fork head clamps 7 Nm SRAM RockShox, 35 Cover cap 28 Nm socket nut, 24 mm SRAM RockShox, Lyrik, Compression damper cover...
  • Page 205 Description SRAM RockShox Locking screw – remote control stop ring Hand-tight or 0.1 … 0.3 Nm 2 mm hex bit SRAM RockShox, Lyrik, Clamping screw – rebound adjuster ring 0.84 Nm 2.5 mm hex bit SRAM RockShox, Lyrik, Air suspension guide rod insert (Select+, Select, Base –...
  • Page 206 Chain guard Brose chain guard bash guard Attachment screws 6 Nm Hex key, 3 mm Chain guard for BOSCH Motor BDU37xx Attachment screws max. 10 Nm M6 × 10; head: max. 5 mm; length: max. 8.5-mm Crank bearing/crank set Conventional cartridge crank bearing 35 …...
  • Page 207 Description BOSCH motor BDU37xx 20 ± 2 Nm Torx Plus® P40, M8 × 16 6 x attachment screws for motor BOSCH Intuvia 100 bracket Torx ® Torx Plus ® Motor cover BOSCH motor cover BDU37xx Attachment screws for lower Initial fitting: 3 ± 0.5 Nm Torx®...
  • Page 208 Description ROHLOFF, 14/500 Chain tensioner attachment screw 8 Nm 5 mm hex bit ROHLOFF, 14/500 Chain guide attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Rear spacer sleeve attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Attachment screw for shift handle on handlebars 1 Nm 2.5 mm hex bit...
  • Page 209 Description SHIMANO, HB-M7000, HB-M6000 HB-M4050 Lock nut 10 … 15 Nm Hub spanner, 13 mm and 17 mm SHIMANO, HB-M7010, HB-M7010-B HB-M6010, HB-M6010-B, HB-M618, HB-M618-B, HB-MT400, HB-MT400-B Lock nut 21 … 26 Nm Hub spanner, 22 mm SHIMANO hub dynamo E2 model 20 - 25 Nm Screw wrench...
  • Page 210 Description SHIMANO DEORE XT SL-M8100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE XT SL-M8130 Attachment screw 3 Nm 4 mm hex bit SHIMANO, SLX SL-M7100 Attachment screw 3 Nm 4 mm hex bit SHIMANO XTR SL-M9100 Attachment screw 3 Nm 4 mm hex bit SRAM AXS Controller...
  • Page 211 Description SHIMANO for MTB/trekking Inner bearing adapter 35 … 50 Nm … SHIMANO for MTB/trekking Top swing screw, clip type 5 … 7 Nm Hex key, 5 mm/ and e-type Screw wrench, 9 mm SHIMANO for MTB/trekking Down swing screw, clip type, 5 …...

  • Page 212: Troubleshooting, Fault Clearance And Repair

    Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Preventing pain The pedelec is both a means of transport and a piece of sports equipment that promotes health. After the first few rides, you may experience sore muscles the next day. However, permanent pain should never occur during or after a ride.

  • Page 213: Sitting Discomfort

    Troubleshooting, fault clearance and repair 9.1.1 Sitting discomfort Around 50% of all pedelec riders experience Solution sitting discomfort: • Adopt an optimal riding position (see • Pressure pain in the sitting bones Section 6.5.2). • Pain in the lower back •...

  • Page 214: Pain In Shoulders And Nape Of Neck

    Troubleshooting, fault clearance and repair 9.1.4 Pain in shoulders and nape of neck The weight of the upper body places a strain on Solution the shoulders due to the bent-forward posture. • A more upright riding position will The more stretched the position is, the more strain immediately reduce pain.

  • Page 215: Knee Pain

    Troubleshooting, fault clearance and repair 9.1.7 Knee pain Pedelec riding is a sport that is easy on the knee Solution joints and is recommended for beginners. Very • Contact specialist dealer. Have the powerful forces are transmitted from the thigh to pedelec adjusted (see Section 6.5).

  • Page 216: Fit Drive System

    Troubleshooting, fault clearance and repair FIT drive system The components of the drive system are checked 7 Insert the battery. constantly and automatically. If an error is 8 Start the drive system. detected, an error message appears on the 9 If the drive system does not start up, remove display.

  • Page 217: Battery Error

    Troubleshooting, fault clearance and repair Symptom Cause Remedy The battery does not perform as well in This does not indicate a problem. winter weather. The journey distance can be shorter 11 Check battery is charged. depending on the road conditions, the gear level and the entire light usage 12 Recharge the battery if it is almost flat.
  • Page 218 Troubleshooting, fault clearance and repair Symptom Cause Remedy 32 Interrupt charging process. 33 Wait a moment. The battery or charger temperature The battery and charger may have exceeded the operating 34 Start charging. become hot. temperature range. 35 If the battery is too hot to touch, there might be a problem with the battery.

  • Page 219: Pinion Error Message

    Troubleshooting, fault clearance and repair 9.2.5 PINION error message 9.2.5.1 Display Warnings The drive system monitors itself continuously and Hazardous situations are indicated with warning indicates a known hazard with a warning symbol symbols on the display screen. or displays a number as an error message if a Symbol Description Method of resolution...
  • Page 220 Troubleshooting, fault clearance and repair Error messages Code Description Method of resolution 0A-0A, Remote-Charger Restart system. 0B-0A Communication Error Switch off system. Disconnect charger from system and socket. Wait until the status LED goes out. Check plug contacts on pedelec and charger and clean if necessary.
  • Page 221 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 0C-0A Remote-Charger Restart system. 0D-0A Charger Authenti- Restart system. Identification Error cation Error Switch off system. Switch off system. Disconnect charger from Disconnect charger from system and socket.
  • Page 222 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 0F-07 Speednode Update Restart system. 12-03, Remote-Battery Switch off system. Error 12-04, Pairing-Error Contact your specialist Remove battery from 12-05, dealer if the problem 12-06 mount.
  • Page 223 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 15-02 Remote-Display Restart system. 16-01 Motor Theft Detection Restart system. Pairing Error Switch off system. Contact your specialist dealer if the problem Remove display from persists.
  • Page 224 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 16-0B Lock Theft Detection Restart system. 17-0B Lock Defective Restart system. Component Contact your specialist Contact your specialist dealer if the problem dealer if the problem persists.
  • Page 225 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 18-0B Lock Start Error Restart system. 21-xx Lock Error Start system. Contact your specialist Contact your specialist dealer if the problem dealer if the problem persists.
  • Page 226 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution Display Software Error 1 2A-xx Restart system. 49-09, Motor Unit Error Check if one or both 49-0A trigger buttons are being Switch off system. held down. If so, release Remove display from buttons.
  • Page 227 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 4D-03 Gear Shift Error Relieve pressure on 51-01 Motor Voltage Error Start system. Relieve pressure on 51-02 Battery Voltage Error pedals so that the Check lighting and its pedals pedelec can switch to cabling for damage.
  • Page 228 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 68-0B Battery Current Error Switch off system. 69-05, Battery Temperature Switch off system. 68-13 Overcurrent Error 69-0A, Error Remove the battery. Leave battery to cool 69-0F, 69-11, down (>...
  • Page 229 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution 6D-xx Unknown Battery Check that the correct 97-xx Charger Check that the correct Error Charging Current battery has been battery has been Error inserted (36 V/48 V). inserted (36 V/48 V).
  • Page 230 Troubleshooting, fault clearance and repair 9.2.5.2 UltraCore battery Description Method of resolution In the event of a hazard, a protective circuit Code: switches the battery off automatically. If a battery fault is detected, the LEDs on the Charge Level indicator will flash. Temperature error Check the battery An authentication error may...

  • Page 231: Correcting Disc Brake Faults

    Troubleshooting, fault clearance and repair 9.2.6 Correcting disc brake faults Symptom Cause Remedy Ringing and unusual  Contact specialist dealer. Fit a city or trekking tyre. sounds from disc brakes. Riding on asphalt with off-road tyres. Dirty or greasy brake disc. ...

  • Page 232: Correcting Faults In The Sr Suntour Suspension Fork

    Troubleshooting, fault clearance and repair 9.2.7 Correcting faults in the SR SUNTOUR suspension fork 9.2.7.1 Rebound too fast The suspension fork rebounds too quickly, Fork head and handlebars are deflected upwards producing a "pogo stick" effect, where the wheel if the wheel bounces back from the ground. Body lifts from the ground in an uncontrolled way.
  • Page 233 Troubleshooting, fault clearance and repair 9.2.7.2 Rebounding too slowly The fork does not rebound quickly enough after The fork remains in a deflected state, causing the absorbing a bump. The fork also remains headset and handlebars to move to a lower deflected over subsequent bumps, which reduces position.
  • Page 234 Troubleshooting, fault clearance and repair 9.2.7.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. The deflection is quickly used up, body weight shifts forward and the pedelec loses some momentum. Figure 195: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
  • Page 235 Troubleshooting, fault clearance and repair 9.2.7.4 Excessively hard damping on bumps When the bike hits a bump, the fork deflects too The headset and handlebars are deflected slowly and the wheel lifts up from the bump. upwards significantly, which can impair control. Traction decreases when the wheel no longer touches the ground.

  • Page 236: Correcting Faults In The Rockshox Rear Frame Damper

    Troubleshooting, fault clearance and repair 9.2.8 Correcting faults in the ROCKSHOX rear frame damper 9.2.8.1 Rebound too fast The rear frame damper rebounds too quickly, Saddle and handlebars are deflected upwards producing a "pogo stick" effect or causing the bike when the wheel bounces back from the ground.
  • Page 237 Troubleshooting, fault clearance and repair 9.2.8.2 Rebounding too slowly The rear frame damper does not rebound quickly The rear frame damper remains in a deflected enough after a bump has been compensated and state after contact with the first bump. When the is not in the required initial position when the rear wheel hits the second bump, the saddle wheel hits the next bump.
  • Page 238 Troubleshooting, fault clearance and repair 9.2.8.3 Suspension too soft on inclines The rear frame damper deflects deeply through to the pedelec rider's weight shifts forward and the the deflection range. Deflection is quickly used up, pedelec loses some momentum. Figure 201: Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 202: Position and shape of the compression adjuster (blue) depends on the model ...
  • Page 239 Troubleshooting, fault clearance and repair 9.2.8.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.

  • Page 240: Correcting Freewheel Faults

    Troubleshooting, fault clearance and repair 9.2.9 Correcting freewheel faults Symptom Cause Remedy Cover forgotten after fitting.  Contact specialist dealer. Check installation correct. Freewheel blocked.  Contact specialist dealer. Measure the length of the socket. If After fitting, socket was compressed by over-tightening the quick-release axle.

  • Page 241: Correcting Lighting Faults

    Troubleshooting, fault clearance and repair 9.2.10 Correcting lighting faults Symptom Cause Remedy The front light or rear light The default settings in the electric drive Take pedelec out of service immediately. does not go on, even system have probably been configured when the switch is Contact specialist dealer.

  • Page 242: Correcting Other Faults And Errors

    Troubleshooting, fault clearance and repair 9.2.13 Correcting other faults and errors Symptom Cause Remedy Two beeps will sound if a Pressed switch mode has been  This is not a malfunction. switch is pressed but the deactivated. switch cannot be operated.

  • Page 243: Repairs At The Specialist Dealer

    Troubleshooting, fault clearance and repair Repairs at the specialist dealer 9.3.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.3.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...

  • Page 244: Replacing The Riding Light

    Troubleshooting, fault clearance and repair 9.3.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 9.3.5 Adjusting the headlight  The headlight must be positioned so that its light beam shines on the road 10 m in front of the pedelec (see Section 6.4).

  • Page 245: Recycling And Disposal

    Recycling and disposal Recycling and disposal This device is marked according to the recycling saves reserves of raw materials and European Directive 2012/19/EU on ensures that all the regulations for protection of waste electrical and electronic health and the environment are adhered to when equipment –...
  • Page 246 Recycling and disposal Waste type Disposal Dispose of Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Cleaning cloths covered in biodegradable oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer.

  • Page 247: Documents

    Documents Documents 11.1 Assembly report Frame number: Date: Components Description Criteria Measures if rejected Assembly Accept- Tests Rejection /inspection ance Front wheel Assembly O.K. Loose Adjust quick release Kickstands Check mount fastening Functional check O.K. Loose Retighten screws Tyre pressure too low/ Tyres Tyre pressure check O.K.
  • Page 248 Documents Components Description Criteria Measures if rejected Assembly Accept- Tests Rejection /inspection ance Drive/gear shift Chain/cassette/ Refasten if necessary or replace Check for damage O.K. Damage sprocket/chainring as specified in parts list Chain guard/spoke Check for damage O.K. Damage Replace as specified in parts list guard Bottom bracket axle/ Check mount fastening...

  • Page 249: Inspection And Maintenance Log

    Documents 11.2 Inspection and maintenance log Diagnosis and documentation of current status Date: Frame number: Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Check mount Kickstands 6 months Functional check O.K.
  • Page 250 Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance Brake system Check mount Handbrake 6 months O.K. Loose Retighten screws fastening Top up brake fluid; Depending on time of take Pedelec out of Brake fluid 6 months Check fluid level O.K.
  • Page 251 Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance Electric drive system Check for damage Functional check O.K. No screen, Restart; test battery; On-board defective new software or new 6 months computer screen display on-board computer; take out of service Check control panel Functional check...
  • Page 252 Documents Notes MY23Z12 - 12_1.0_26.01.2024...

  • Page 253: Glossary

    Glossary Glossary Bicycle for young adults Disc brake Source: ISO 4210-2: bicycle designed for use on Source: EN 15194:2017: brake in which brake public roads by a young adult whose weight is less pads are used to grip the lateral faces of a thin than 40 kg, with maximum saddle height of disc attached to or incorporated into the wheel 635 mm or more and less than 750 mm.
  • Page 254 Glossary Fork steerer Maximum tyre pressure Source: EN 15194:2017: part of a fork that rotates Source: EN 15194:2017: maximum tyre pressure around the steering axis of a pedelec frame head recommended by the tyre or rim manufacturer for tube. It is normally connected to the fork crown or a safe and efficient performance.
  • Page 255 Glossary Operating instructions Seat post Source: ISO/DIS 20607:2018: part of the user Source: EN 15194:2017: component that clamps information that machine manufacturers provide the saddle (with a bolt or assembly) and connects to machine operators; it contains guidance, it to the frame. instructions and tips related to the use of the Shut-off speed machine in all its life cycle phases.

  • Page 256: Abbreviations

    Glossary 12.1 Abbreviations Weight of the ready-to-ride pedelec Source: ZEG: the indicated weight for a ready-to- Abbreviation Meaning/derivation ride pedelec refers to the weight of a pedelec at the time of sale. The weight of each additional Anti-blocking system accessory must be added to this weight Bluetooth Low Energy EPAC Electric power-assisted cycle...

  • Page 257: Appendix

    Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* ZEG Zweirad-Einkaufs-Genossenschaft eG c/o ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Strasse 2 Longericher Strasse 2 50739 Köln 50739 Köln Germany Germany The machine, pedelec types: ZA-15-0017 Vuca Evo X1 City and trekking bicycle ZA-15-0018 Vuca Evo FSX1...

  • Page 258: Keyword Index

    Keyword index Keyword index torque, 202 torques 206 Brake disc, 47 Chain stay, 27 Air valve, 35 - check, 175 Chain wheel, 52 position, 35 - clean 162 Chain wheels, Articulated shaft, - replace, 243 - clean, 162 - maintain 167 position, 47 Chain, 52 Axle,...
  • Page 259 Keyword index electric, 53 - check electric gear shift, Dual pivot rim brake, Initial commissioning, 75 torque, 203 - switch gears, 150 Dunlop valve, see conventional Guard, Jockey wheel, valve position, 24 - maintain 167 Dust seal, 40 Guards, - check 156 Kickstand, Electrical control system, 253 - clean, 160...
  • Page 260 Keyword index Placing on the market, 255 Riding light, -Position, 24 - adjust, 121 Negative deflection, 254 Position, 24 - check, 157, 179 Nipple holes, Pressure point, 255 - switch off 142 - check, 173 Puncture protection belt, 43 Rim brake locking lever 46 Nipple well, position, 41 Rim, 43...
  • Page 261 Keyword index Shut-off speed, 255 Tyres,- Tube-type tyres 41 Size, 27 Slicks, 42 Underride guard, Slippage, 255 torque, 211 Spare part, 255 Unit, Spoke nipples, 44 - changing 62 - maintain, 167 USB cover, position, 41 - check 157 Spokes, 44 - check, 173 - replace 243 Valve, 41...

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