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TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
EN
18-17-1001, 18-17-1002, 18-18-1063, 18-18-1064, 18-18-1065, 18-18-1066, 18-18-1067,
18-18-1068, 18-18-1500, 18-19-1001
034-03217 • 1.0 • 4 December 2018
Lacuba
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE FOR LATER REFERENCE
Electric bicycle
EN_034-03217_1.0_BULLS Brose Bloks MY19_COVER.book Page 1 Tuesday, December 4, 2018 3:28 PM
Copyright
© ZEG Zweirad-Einkaufs-Genossenschaft eG
Distribution or reproduction of these operating instructions
and utilisation or communication of their content is prohibited
unless expressly approved. Any infringement will render the
offender liable for compensation. All rights reserved in the
event that a patent, utility model or industrial design is
registered.
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034-03217_1.0_04.12.2018 1
Data sheet
Surname, first name of the purchaser:
Date of purchase:
Model:
Frame number:
Type number:
Unladen weight (kg):
Tyre size:
Recommended tyre pressure (bar)*: front: rear:
Wheel circumference (mm):
Company stamp and signature:
*After a tyre change, refer to the tyre markings for the permitted tyre
pressures and make sure that they are observed. The recommended tyre
pressure must not be exceeded.
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Table of contents
034-03217_1.0_04.12.2018
2
Table of contents
1 About these instructions 9
1.1 Manufacturer 9
1.2 Laws, standards and directives 10
1.3 Other valid documents 10
1.4 Subject to change 11
1.5 Language 11
1.6 For your safety 12
1.6.1 Instruction, training and customer service 12
1.6.2 Basic safety notes 13
1.6.3 Warnings 13
1.6.4 Safety markings 14
1.7 For your information 14
1.7.1 Instructions for actions 14
1.7.2 Information on the type plate 14
1.7.3 Language conventions 16
1.8 Type plate 18
1.9 Identifying 19
1.9.1 Operating instructions 19
1.9.2 Bicycle 19
2 Safety 20
2.1 Requirements for the rider 20
2.2 Hazards for vulnerable groups 20
2.3 Personal protective equipment 20
2.4 Proper use 21
2.4.1 City and trekking bicycle 21
2.4.2 Mountain bike 22
2.5 Improper use 23
2.5.1 City and trekking bicycle 23
2.5.2 Mountain bike 24
2.6 Duty to take care 24
2.6.1 Rider 24
2.6.2 Operator 25
3 Description 26
3.1 Overview 26
3.2 Wheel and fork 27
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Table of contents
3.2.1 Valve 27
3.2.2 Suspension 29
3.2.3 Suspension fork structure 30
3.2.3.1 Air suspension fork structure 31
3.2.3.2 Structure of the FOX rear frame damper 32
3.2.3.3 Structure of the Suntour rear frame damper 33
3.3 Brake system 34
3.4 Electric drive system 35
3.5 Drive system 35
3.5.1 Rechargeable battery 37
3.5.1.1 Charge status indicator 38
3.5.1.2 Range 39
3.5.2 Driving light 39
3.5.3 Operating element 39
3.5.3.1 Indicators 41
3.5.3.2 Speed 41
3.5.3.3 Level of assistance 42
3.5.3.4 Journey information 42
3.5.3.5 Charge status indicator 43
4 Technical data 44
5 Transportation, storage and assembly 47
5.1 Transportation 47
5.1.1 Transporting the battery 49
5.1.2 Using the transport securing system 49
5.2 Storing 50
5.2.1 Break in operation 51
5.2.1.1 Preparing a break in operation 51
5.2.1.2 Taking out of operation 51
5.3 Assembly 52
5.3.1 Required tools 52
5.3.2 Unpacking 53
5.3.3 Scope of delivery 53
5.3.4 Commissioning 54
5.3.4.1 Checking the battery 56
5.3.5 Mounting the wheel in the Suntour fork 57
5.3.5.1 Mounting the wheel with screw-on axle (15 mm) 57
5.3.5.2 Mounting the wheel with screw-on axle (20 mm) 59
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4
5.3.5.3 Mounting the wheel with a quick release axle 60
5.3.6 Mounting the wheel with a quick release 64
5.3.7 Mounting the wheel in the FOX fork 67
5.3.7.1 Mounting the wheel with the quick release (15 mm) 67
5.3.7.2 Adjusting the FOX quick release 68
5.3.7.3 Mounting the wheel with Kabolt axles 70
5.3.7.4 Checking the stem and handlebars 71
5.3.8 Sale of the bicycle 72
6 Before the first ride 73
6.1 Adjusting the saddle 73
6.1.1 Adjusting the saddle tilt 73
6.1.2 Determining the seat height 74
6.1.3 Adjusting the seat height with quick release 75
6.1.4 Setting the height-adjustable seat post 77
6.1.4.1 Lowering the saddle 77
6.1.4.2 Raising the saddle 77
6.1.5 Adjusting the seat position 78
6.2 Adjusting the handlebars 79
6.2.1 Adjusting the height of the handlebars 80
6.2.2 Turning the handlebars to the side 81
6.2.2.1 Checking the clamping force of the quick releases 82
6.2.2.2 Adjusting the quick release clamping force 82
6.3 Adjusting the brake lever 83
6.3.1 Adjusting the pressure point on a Magura brake lever 83
6.3.2 Adjusting the grip distance 84
6.3.2.1 Adjusting the grip distance on a Magura brake lever 85
6.4 Adjusting the suspension of the Suntour fork 86
6.4.1 Adjusting the negative deflection 87
6.4.1.1 Adjusting the air suspension fork negative deflection 87
6.4.1.2 Adjusting the steel suspension fork negative deflection 89
6.4.2 Adjusting the rebound 90
6.4.3 Setting the compression 91
6.5 Adjusting the suspension of the FOX fork 92
6.5.1 Adjusting the negative deflection 92
6.5.2 Adjusting the rebound 95
6.5.3 Setting the compression 96
6.6 Adjusting the rear frame damper 97
6.6.1 Adjusting the negative deflection 97
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Table of contents
6.6.2 Setting the compression 99
6.6.3 Adjusting the rebound 100
6.7 Retracting brake linings 101
7 Operation 102
7.1 Before each ride 104
7.2 Check list before each ride 105
7.3 Using the kickstand 106
7.4 Using the pannier rack 107
7.5 Rechargeable battery 109
7.5.1 Removing the battery 111
7.5.2 Inserting the battery 111
7.5.3 Charging the battery 112
7.5.4 Waking the battery 113
7.6 Electric drive system 114
7.6.1 Switching on the drive system 114
7.6.2 Activating the standby mode 114
7.6.3 Switching off the drive system 115
7.7 Electric drive system 116
7.7.1 Switching on the drive system 116
7.7.2 Waking the drive system 116
7.7.3 Switching off the drive system 117
7.8 Control panel with display 118
7.8.1 Removing and attaching the display 118
7.8.2 Using the driving light 119
7.8.3 Using the push assist system 120
7.8.4 Selecting the level of assistance 121
7.8.5 Switching the journey information 121
7.8.6 Using the USB port 121
7.8.7 Changing the system information 122
7.9 Control panel with display 123
7.9.1 Using the driving light 123
7.9.2 Using the push assist system 123
7.9.3 Selecting the level of assistance 124
7.9.4 Changing the kilometre display unit 124
7.9.5 Switching journey information 124
7.9.5.1 Deleting trip distance 125
7.10 Gear shift 126
7.10.1 Selecting gears 126
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6
7.10.2 Using the derailleur gears 127
7.10.3 Using a hub gear 128
7.11 Brake 130
7.11.1 Using the brake lever 134
7.11.2 Using the back-pedal brake 134
7.12 Suspension and damping 135
7.12.1 Adjusting the compression of the Suntour fork 135
7.12.2 Adjusting the compression of the Fox fork 136
7.12.3 Adjusting the compression of the Fox fork 137
8 Maintenance 139
8.1 Cleaning and servicing 141
8.1.1 After each ride 141
8.1.1.1 Cleaning the suspension fork 141
8.1.1.2 Cleaning the rear frame damper 141
8.1.1.3 Cleaning the pedals 141
8.1.2 Basic cleaning 142
8.1.2.1 Cleaning the frame 143
8.1.2.2 Cleaning the stem 143
8.1.2.3 Cleaning the rear frame damper 143
8.1.2.4 Cleaning the wheel 143
8.1.2.5 Cleaning the drive elements 144
8.1.2.6 Cleaning the chain 144
8.1.2.7 Cleaning battery 145
8.1.2.8 Cleaning the display 145
8.1.2.9 Cleaning the drive unit 146
8.1.2.10 Cleaning the brake 146
8.1.3 Servicing 147
8.1.3.1 Servicing the frame 147
8.1.3.2 Servicing the stem 147
8.1.3.3 Servicing the fork 147
8.1.3.4 Servicing the drive elements 147
8.1.3.5 Servicing the pedal 147
8.1.3.6 Servicing the chain 148
8.1.3.7 Servicing the drive elements 148
8.2 Maintenance 149
8.2.1 Wheel 149
8.2.2 Brake system 150
8.2.3 Electrical cables and brake cables 150
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Table of contents
8.2.4 Gear shift 150
8.2.5 Stem 151
8.2.6 Checking the chain and belt tension 151
8.2.7 USB port 152
8.2.8 Suspension fork 152
8.3 Service 153
8.4 Adjusting and repairing 155
8.4.1 Use original parts and lubricants only 155
8.4.2 Wheel quick release 156
8.4.2.1 Clamping the clamping lever 157
8.4.2.2 Clamping version I 157
8.4.2.3 Clamping version II 158
8.4.2.4 Clamping version III 159
8.4.2.5 Clamping version IV 160
8.4.2.6 Clamping version V 161
8.4.3 Adjusting the tyre pressure 163
8.4.3.1 Dunlop valve 163
8.4.3.2 Presta valve 164
8.4.3.3 Schrader valve 165
8.4.4 Adjusting the gear shift 166
8.4.5 Cable-operated gear shift, single-cable 166
8.4.6 Cable-operated gear shift, dual-cable 167
8.4.7 Cable-operated twist grip, dual-cable 168
8.4.8 Offsetting the brake lining wear 169
8.4.9 Hydraulically operated rim brake 169
8.4.10 Hydraulically operated disc brake 170
8.4.11 Replacing the lighting 170
8.4.12 Setting the headlight 170
8.4.13 Repair by the specialist dealer 170
8.4.14 Replacing the lighting 171
8.4.15 Setting the headlight 171
8.4.16 Repair by the specialist dealer 171
8.4.17 First aid 172
8.4.18 The drive system or display do not start up 173
8.4.18.1 System messages 174
8.4.18.2 Special system messages 174
8.5 Accessories 177
8.5.1 Child seat 177
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8
8.5.2 Bicycle trailer 179
8.5.3 Pannier rack 180
9 Recycling and disposal 181
9.1 EC declaration of conformity 183
9.2 Parts list 184
9.3 Table of figures 193
9.4 List of tables 197
9.5 Index 199
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034-03217_1.0_04.12.2018 9
About these instructions
1 About these instructions
Read these operating instructions before
commissioning the bicycle to ensure you use all the
functions correctly and safely. The operating
instructions are not a substitute for personal
instruction by the supplying specialist dealer. The
operating instructions are a component part of the
bicycle. Therefore, if it is re-sold at a later time, they
must be handed over to the subsequent owner.
These operating instructions are mainly intended for
the rider and operator of the bicycle, who tend to be
non-professionals.
Staff at all specialist dealers have specialist training
and qualifications, and are therefore capable of
identifying risks and preventing hazards which may
arise during maintenance, servicing and repairs on the
bicycle. Information for specialist staff does not require
non-professionals to take any action.
1.1 Manufacturer
The manufacturer of the bicycle 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
Text passages which are expressly intended for
specialist staff (e.g. bicycle mechanics) are clearly
marked with a tool symbol.
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About these instructions
034-03217_1.0_04.12.2018
10
1.2 Laws, standards and directives
These operating instructions comply with the essential
requirements from:
Machinery Directive 2006/42/EC,
Electromagnetic Compatibility Directive 2014/30/EU,
EN ISO 12100:2010 Safety of machinery – General
principles of design Risk assessment and reduction,
EN 15194:2015, Cycles – Electrically power assisted
cycles – EPAC bicycles,
EN ISO 4210, Cycles – Safety requirements for
bicycles,
EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods,
EN 82079-1:2012, Preparation of instructions for use
– Structuring, content and presentation – Part 1:
General principles and detailed requirements and
EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
1.3 Other valid documents
These operating instructions are only complete in
conjunction with the other valid documents.
The following document applies for this product:
Charger operating instructions.
No other information is also applicable.
The constantly updated lists of approved accessories
and parts are available to specialist dealers.
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034-03217_1.0_04.12.2018 11
About these instructions
1.4 Subject to change
The information contained in these operating
instructions are the approved technical specifications
at the time of printing. Any significant changes are
included in a new issue of the operating instructions.
You will find any modifications to these operating
instructions at:
www.bulls.de/service/downloads
1.5 Language
The original operating instructions are written in
German. A translation is not valid without the original
operating instructions.
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About these instructions
034-03217_1.0_04.12.2018
12
1.6 For your safety
The safety concept of the bicycle comprises four
elements:
rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer,
the chapter on general safety,
the warnings in these instructions and
the safety marking on the type plates.
1.6.1 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 in the data sheet. If
you are unable to contact your specialist dealer, you
will find other specialist dealers at www.zeg.de.
The rider or the operator of the bicycle will be
instructed in person on the bicycle functions when the
supplying specialist dealer hands over the bicycle, if
not before. This instruction particularly covers the
bicycle's electrical functions and correct use of the
charger.
Each rider to whom this bicycle is provided must
receive instruction on the bicycle's functions. The
operating instructions must be submitted to each rider
in printed form and must be acknowledged and
adhered to.
The specialist dealer authorised to perform repairs and
maintenance work receives regular training.
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034-03217_1.0_04.12.2018 13
About these instructions
1.6.2 Basic safety notes
1.6.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating instructions
are shown as follows:
The following pictograms and signal words are used in
the operating instructions for warnings and information
notices:
These operating instructions have a chapter with
general safety notes [Chapter 2, page 20]. You can
distinguish this chapter as it has a grey background.
Type and source of the danger
Description of the danger and the consequences.
Measures
SIGNAL WORD
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.
May lead to material damage if ignored.
Table 1: Meanings of the signal words
DANGER
!
WARNING
!
CAUTION
!
NOTICE
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About these instructions
034-03217_1.0_04.12.2018
14
1.6.4 Safety markings
The following safety markings are used on the
bicycle's type plates:
1.7 For your information
1.7.1 Instructions for actions
Instructions for actions are structured in accordance
with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)
1.7.2 Information on the type plate
Alongside the warnings, the type plates of the
products also contain other important information on
the bicycle:
General warning
Adhere to the instructions for use
Table 2: Safety markings on the product
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034-03217_1.0_04.12.2018 15
About these instructions
only suitable for the road, no off-road riding or jumps
suitable for roads, off-road riding and jumps of up to
15 cm
suitable for rough off-road riding and jumps of up to
61 cm
suitable for rough off-road riding and jumps of up to
122 cm
suitable for the most difficult terrain
Table 3: Area of use
City and trekking bicycle
Child's bicycle / bicycle for young adults
BMX bicycle
Mountain bike
Racing bicycle
Carrier bicycle
Folding bicycle
Table 4: Bicycle type
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About these instructions
034-03217_1.0_04.12.2018
16
1.7.3 Language conventions
The bicycle described in these operating instructions
may be equipped with alternative components. The
equipment of the bicycle is defined by the respective
type number. If applicable, the notes alternative
equipment and alternative version make reference to
the use of alternative components.
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)
Must not be thrown into water (immersed)
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Table 5: Information on the type plate
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034-03217_1.0_04.12.2018 17
About these instructions
Alternative equipment describes additional components
which are not necessarily an integral part of every
bicycle in these instructions.
Alternative version explains the various variants of
components if they differ in use.
The following terms are used for better legibility:
The following conventions are used in these operating
instructions:
Term Meaning
Operating
instructions
Original operating instructions
or translation of the original
operating instructions
Bicycle Electric motor driven cycle
Motor Drive motor
Convention Use
Italics Entry in the index
SPACED Indicators on the display
screen
[Example, page
numbering]
Cross references
Bulleted lists
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About these instructions
034-03217_1.0_04.12.2018
18
1.8 Type plate
The type plate is situated on the frame. The type plate
features the following information:
Figure 1: Type plate, example
1 CE marking
2 Manufacturer
3 Type number
4 Nominal continuous power
5 Permitted total weight
6 Year of manufacture
7Bicycle type
8Safety instructions
9Disposal instruction
10 Area of use
11 Model year
12 Weight of the ready-to-ride bicycle
13 Shut-off speed
ZEG Zweirad-Einkaufs-
Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
Typ:
19-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2018 / MJ 2019
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
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034-03217_1.0_04.12.2018 19
About these instructions
1.9 Identifying
1.9.1 Operating instructions
The identification number of these operating
instructions is made up of the document number, the
version number and the release date. It can be found
on the cover page and in the footer.
1.9.2 Bicycle
These BULLS operating instructions refer to the model
year 2019. The production period is from August 2018
to July 2019. They are issued in August 2018.
The operating instructions are a component part of the
following bicycles:
Identification number 034-03217_1.0_04.12.2018
Table 6: Identification number of the operating instructions
Type
number Model Bicycle type
19-17-1007 Sturmvogel Evo City and trekking bicycle
19-17-1008 Sturmvogel Evo Street City and trekking bicycle
19-17-1052 Sturmvogel Evo Street City and trekking bicycle
19-18-1020 E-Stream Evo 1 29 Mountain bike
19-18-1021 E-Stream Evo 2 29 Mountain bike
19-18-1022 E-Stream Evo 1 27.5+ Mountain bike
19-18-1023 E-Stream Evo 1 29 Mountain bike
19-18-1027 E-Stream Evo TR2 Mountain bike
19-18-1053 E-Stream Eva TR3 Mountain bike
19-18-1059 E-Stream Evo 2 27.5+ Mountain bike
19-18-1060 E-Stream Evo TR3Mountain bike
19-18-1060 E-Stream Evo 3 29 Mountain bike
19-18-1061 E-Stream Evo AM3 Mountain bike
19-18-1062 E-Stream Evo AM4 Mountain bike
19-18-4013 E-Stream Evo 2 27.5+ Mountain bike
19-18-4013 E-Stream Eva 2 27.5+ Mountain bike
19-18-4014 E-Stream Eva 1 27.7+ Mountain bike
19-18-4015 E-Stream Eva TR2 Mountain bike
Table 7: Bicycle definition by type number, model and bicycle type
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!!
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Safety
034-03217_1.0_04.12.2018
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2 Safety
2.1 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 14 years of age and
have experience with muscle-powered bicycles.
The physical and mental abilities of the rider must be
sufficient for riding on public roads.
2.2 Hazards for vulnerable groups
and charger must be kept out of the reach of children.
If the bicycle is used by minors, 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 bicycle is being
used as per these operating instructions. Legal
guardians hold sole responsibility for determining
whether minors are capable of using the bicycle.
2.3 Personal protective equipment
We recommend that you wear a suitable safety
helmet. We also recommend that you wear typical,
long, close-fitting cycling clothing and sturdy footwear.
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034-03217_1.0_04.12.2018 21
Safety
2.4 Proper use
The bicycle is designed to support a maximum speed
of 25 km/h. The bicycle may only be used in a perfect,
fully functional condition.
National requirements may apply to the bicycle which
differ from the standard equipment. For riding on
public roads, some special regulations apply in
relation to the driving 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 must be met. Approved
accessories can be installed by specialist staff.
Changing the drive to increase power is not permitted.
Each bicycle is assigned a bicycle type, which
determines its proper use and area of use.
2.4.1 City and trekking bicycle
City and trekking bicycles are designed for daily,
comfortable use. They are suitable for riding on public
roads.
Area of use:
Suitable for tarmacked and paved roads.
Suitable for tarmacked roads, cycle paths and firm
gravel paths and roads, and longer sections with
moderate slopes and jumps up to 15 cm.
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Safety
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2.4.2 Mountain bike
The mountain bike is designed for sporting use. The
design characteristics include a short wheelbase, a
sitting position with the rider inclined towards the front,
and a brake requiring low actuation force.
A mountain bike is a piece of sporting equipment. It
requires an adaptation period as well as physical
fitness. Use requires the appropriate training; in
particular riding in bends and braking should be
practised.
The strain on the rider, in particular the hands and
wrists, arms, shoulders, neck and back, is accordingly
high. Inexperienced riders tend to brake excessively
and lose control as a result.
Area of use:
Suitable for tarmacked roads, cycle paths and easy to
demanding off-road riding, sections with moderate
slopes and jumps up to 61 cm.
Suitable for tarmacked roads, cycle paths and easy to
demanding off-road riding, limited downhill use and
jumps up to 122 cm.
Suitable for tarmacked roads, cycle paths and easy to
extremely difficult off-road riding, unlimited downhill
use and any jumps
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034-03217_1.0_04.12.2018 23
Safety
2.5 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. The bicycle is
not suitable for the following uses:
when the electrical drive system has been
manipulated
when the permitted gross load weight is exceeded
riding with a damaged or incomplete bicycle
riding over steps
riding through deep water
lending the bicycle to untrained riders
carrying other people
riding with excessive luggage
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.
2.5.1 City and trekking bicycle
City and trekking bicycles are not sports bicycles. If
used for sports, the rider can expect reduced riding
stability and diminished comfort.
Non-permitted areas of use:
Never drive off-road or perform jumps.
Never drive off-road or perform jumps over 15 cm.
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2.5.2 Mountain bike
A mountain bike must be retrofitted with lighting, a
guard etc. according to the applicable national laws
and regulations before it can be used in public street
traffic.
Non-permitted areas of use:
2.6 Duty to take care
The safety of the bicycle can only be assured if all the
necessary measures are taken.
2.6.1 Rider
The rider:
receives instruction before the first ride. They can
clarify any questions relating to the operating
instructions with the operator or specialist dealer
wears personal protective equipment.
assumes all the obligations of the operator in case the
bicycle changes hands.
Never ride downhill or perform jumps over 61 cm.
Never traverse extremely difficult off-road terrain or
perform jumps over 122 cm.
Never exceed your personal limits.
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Safety
2.6.2 Operator
The operator has the duty of care and responsibility for
scheduling these measures and checking that they are
implemented.
The operator:
makes these operating instructions available to the
rider for the duration of use of the bicycle. If
necessary, they translate the operating instructions
into a language which the rider understands.
familiarises the rider with the functions of the bicycle
before the first ride. Only riders who have received
instruction may be allowed to ride.
instructs the rider on proper use and the wearing of
personal protective equipment.
only employs specialist staff for maintenance and
repair of the bicycle.
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3 Description
3.1 Overview
Figure 2: Bicycle from right; E-Stream EVA 2 27.5+, 27 used as example
1Front wheel
2Fork
3Handlebars
4Stem
5Frame
6 Seat post
7 Saddle
8Rear wheel
9 Chain
10 Rechargeable battery, frame number and type
plate
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Description
3.2 Wheel and fork
Figure 3: Components of the wheel – example showing front wheel
1 Tyre
2Rim
3 Suspension fork head with setting wheel
4Fork
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of the suspension fork
3.2.1 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 bicycle either has a classical Dunlop valve, a
Presta valve or a Schrader valve.
1
2
4
5
8
7
3
9
6
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Dunlop valve
Presta valve
Schrader valve
The rider can easily exchange the
valve and quickly release the air. The
air pressure cannot be measured with
this valve.
The Presta valve requires a smaller
hole in the rim, which is why it is
especially suitable for the narrow rims
of racing bicycles. The air pressure
can be measured with this valve.
The rider can fill the Schrader valve
very easily at a petrol station. The air
pressure can be measured with this
valve.
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Description
3.2.2 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: Bicycle 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.
12
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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.
3.2.3 Suspension fork structure
Figure 5: Example showing Suntour fork: The stem and handlebars are
fastened to the fork shaft (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)
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Description
3.2.3.1 Air suspension fork structure
The fork of the bicycle features both air suspension and a
compression damper, in addition to a rebound damper in
some cases.
Figure 6: Example showing a Yari fork – diagram with the operating
elements: 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)
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3.2.3.2 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
25-30%
1
2
4
3
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Description
3.2.3.3 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
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3.3 Brake system
The bicycle's brake system comprises a hydraulic rim
brake on both the front and rear wheel.
Figure 9: Bicycle brake system with a disc brake, example
1Brake disc
2 Brake calliper with brake linings
3Handlebars with brake levers
4 Front wheel brake disc
5 Rear wheel brake disc
On a bicycle with a disc brake, the brake disc is
screwed permanently to the hub of the wheel.
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 movement of the wheel is decelerated until it
comes to a stop.
2
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Description
3.4 Electric drive system
3.5 Drive system
The bicycle is driven by muscle power via 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 10: Diagram of drive system
1 Direction of travel
2Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
5
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The bicycle also has an integrated, electric drive
system. The electric drive system is made up of six
components:
Figure 11: Diagram of electric drive system
1Headlight
2Operating element
3 Rechargeable battery
4 Rear light
5Motor
a charger which is designed for this 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 assistance depends on the force
applied to the pedals by the rider. Drive system
assistance is therefore only activated when the rider
pedals. This happens regardless of the selected level
of assistance. 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. If the
speed falls below 25 km/h, the assistance is
automatically activated again.
2
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Description
A push assist system can be activated. The push
assist continues to drive the bicycle as long as the
rider pushes the plus button on the handlebars. The
speed can be a maximum of 6 km/h in this case.
3.5.1 Rechargeable battery
The lithium ion battery has an internal electronic
protection circuit. It is matched to the charger and the
bicycle. 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. The battery's service life can
be extended if it is well maintained and, above all,
stored at the correct temperatures. The battery charge
status 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 bicycle has two types of battery: either an Evo 650
battery or a SuperCore battery
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 8: Rechargeable battery technical data
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Figure 12: Evo 650 battery details
with battery lock (1), port for charger plug (2), On-Off
button (3), operating and charge status indicator (4), top of
down tube (5) and swung-out battery (6)
3.5.1.1 Charge status indicator
The five green LEDs on the charge status indicator
show the battery charge status when the battery is
switched on. Each LED represents 20% of the charge
status. The charge status of the switched-on battery is
also shown on the display.
If the battery charge status falls below 5%, all the
LEDs on the operating and charge status indicator will
go out. However, the charge status is still shown on
the display.
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Description
3.5.1.2 Range
The range is influenced by many factors, such as:
Level of assistance: The higher the selected level of
assistance, the lower the range.
gear switching habits,
•tyre type,
tyre pressure,
the age, condition and charge status of the battery,
route profile (slopes) and route quality (road surface),
weather conditions (e.g. opposing winds, ambient
temperature, etc.),
e-bike weight and
load.
3.5.2 Driving light
When the driving light is activated, the headlight and
the rear light are switched on.
3.5.3 Operating element
The operating element controls the drive system and
shows the journey data.
The bicycle's battery supplies the display with energy
when a sufficiently charged battery is inserted on the
bicycle and the drive system is switched on.
Storage temperature 5 °C–25 °C
Charging ambient temperature -1C - +6C
Table 9: Operating element technical data
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The operating element consists of an LCD display,
2 rocker switches and 3 buttons.
Figure 13: Display details
4
Use
1Plus button
2On-Off button
3Light button
4Settings button
5LCD display
6Minus button
Table 10: Display overview
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Description
3.5.3.1 Indicators
The operating element display has six on-screen
indicators:
Figure 14: On-screen indicators overview
3.5.3.2 Speed
The current speed is displayed on the speed indicator.
In the settings, you can select whether the speed is
displayed in kilometres or miles. The selected unit of
measure is displayed on the speed indicator.
Use
1 Speed indicator
2 Selected journey information indicator
3Trip distance or range indicator
4 Level of assistance
5 Selected unit of measure for speed
6 Charge status indicator
Table 11: On-screen indicator overview
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3.5.3.3 Level of assistance
The higher the selected level for assistance, the more
the drive system assists the rider when pedalling. The
following levels of assistance are available.
3.5.3.4 Journey information
The display shows three pieces of journey information:
The displayed journey information can be switched.
The display shows up to 9999 kilometres of
6213 miles. If the kilometre counter reaches more than
999 kilometres, it will be reset to 0 again.
Display Level of assistance
Level 4: Highest level of assistance
with the most power, battery empties
fastest.
Level 3: The second-highest level of
assistance
Level 2: The second-lowest level of
assistance
Level 1: The lowest level of
assistance, the battery charge is
preserved the longest.
Level 0 (off): Riding without
assistance, the bicycle functions like a
normal bicycle.
Table 12: Levels of assistance display l
Screen display Function
TRP Trip distance
RRemaining bicycle range
TTotal trip distance completed by bicycle
Table 13: Journey information
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Description
3.5.3.5 Charge status indicator
The charge status indicator consists of 5 segments.
Every segment shows 20% of the battery charge
status.
If the charge status of the battery drops to 10% or less,
the last segments will start to flash in order to indicate
the low charge status.
Screen display Battery charge status
81 - 100%
61 - 80%
41 - 60%
21 - 40%
11 - 20%
(Indicator flashes) < 10%
Table 14: Battery charge status indicator
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4 Technical data
Bicycle
Evo 650 rechargeable battery
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
Operation temperature 5 °C–35 °C
Working environment temperature 15 °C–25 °C
Charging temperature 10 °C–30 °C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 15: Bicycle technical data
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 16: Rechargeable battery technical data
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Technical data
SuperCore rechargeable battery
Operating element
Voltage 37 V / 42.0 V
Energy 750 W / 20 Ah
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 17: Rechargeable battery technical data
Indicator type LCD (Liquid Crystal Display)
Colour Monochrome
Display size 1.4 inch / 35.4mm
Dimensions (W x L x H) 22 mm x 46 mm x 51 mm
Display pane Hard-coated PMMA (polymethyl
methacrylate) acrylic glass lens
Protection class IP67
Weight with cable 58 g
Table 18: Operating element technical data
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Emissions
USB port
Tightening torque
A-weighted emission sound pressure level < 70 dB(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 19: Emissions from the bicycle*
*The safety requirements as per Electromagnetic Compatibility
Directive 2014/30/EU have been met. The bicycle and the
charger can be used in residential areas without restriction
Charge voltage 5 V
Charging current max. 500 mA
Table 20: USB port technical data
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque* 5Nm - 7Nm
Table 21: Tightening torque values
*if there is no other data on the component
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Transportation, storage and assembly
5 Transportation, storage and
assembly
5.1 Transportation
Crash caused by unintentional activation
There is a risk of injury if the drive system is activated
unintentionally.
Remove the battery before the bicycle 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.
Oil leak if no transport securing device
The brake securing device prevents the brakes from
being applied accidentally during transport. 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.
If the bicycle is lying flat, oil and grease may leak from
the bicycle.
If the shipping box with a bicycle is lying flat or on one
end, it does not provide the frame and the wheels with
adequate protection from damage.
Only transport the bicycle in an upright position.
CAUTION
!
CAUTION
!
CAUTION
!
NOTICE
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Take into account the ready-to-use bicycle's weight
when transporting it.
Remove the display and the batteries before
transporting the bicycle.
Protect the electrical components and connections
on the bicycle from the elements with suitable
protective covers.
Remove accessories, for example drinking bottles,
before transportation of the bicycle.
When transporting by car, you must use a suitable
bicycle rack system.
Transport the bicycle in a dry, clean place where it
is protected from direct sunlight.
Bicycle rack systems which secure the bicycle
standing on its head by the handlebars or frame,
generate inadmissible forces on the components
during transportation. This can cause the supporting
parts to break.
Never use bicycle rack systems which secure the
bicycle standing on its head by the handlebars or
frame.
NOTICE
The specialist dealer will advise you on how to select
a suitable rack system properly and how to use it
safely.
When shipping the bicycle, we recommend that you
have the bicycle partially dismantled in the proper
manner and packaged by the specialist dealer.
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Transportation, storage and assembly
5.1.1 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. The parcel service must be made
aware of the presence of hazardous goods in the
packaging.
5.1.2 Using the transport securing system
Insert the transport securing devices between the
brake linings.
The transport securing device is squeezed between
the two linings.
Figure15: Fastening the transport securing device
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5.2 Storing
If the bicycle 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 bicycle with a hydraulic seat post upside
down on the floor; otherwise you, will damage the seat
post lever.
Store the bicycle, battery and charger in a dry, clean
location.
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage batteries.
Batteries may self-ignite and explode.
Protect batteries against heat.
Never expose batteries to sustained direct sunlight.
If the bicycle is lying flat, oil and grease may leak from
the bicycle.
If the shipping box with a bicycle is lying flat or on one
end, it does not provide the frame and the wheels with
adequate protection from damage.
Only store the bicycle in an upright position.
CAUTION
!
NOTICE
Storage temperature 5 °C–25 °C
Ideal storage temperature 10 °C–15 °C
Table 22: Storage temperature for batteries, the bicycle and charger
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Transportation, storage and assembly
5.2.1 Break in operation
If the bicycle is to be removed from service for longer
than four weeks, e.g. in winter, a break in operation
has to be prepared.
5.2.1.1 Preparing a break in operation
Enable display storage mode.
Remove the battery from the bicycle.
Charge the battery to around 60% (three to four LEDs
of the charge status indicator light up).
The bicycle has 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 servicing and basic cleaning and apply
preservative agent.
5.2.1.2 Taking out of operation
Store the bicycle, battery and charger in a dry,
clean environment.
Check the charge status of the battery after 8 weeks.
If only one LED on the charge status indicator lights
up, recharge the battery to around 60%.
The battery discharges when not in use. This can
cause irreparable damage to the battery.
The battery must be recharged every 8 weeks.
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.
NOTICE
NOTICE
NOTICE
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5.3 Assembly
If a fitting stand is used, it must be approved for a
maximum weight of 30 kg.
To reduce the weight, we recommend that you always
disconnect the battery from the bicycle for the duration
of use of the fitting stand.
5.3.1 Required tools
The following tools are required to assemble the
bicycle:
•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 5 and
40 Nm
Twelve-point square socket T-25
Ring spanner (8 mm, 9 mm, 10 mm, 13 mm, 14 mm
and 15 mm) and
Cross, flat head and ordinary screwdriver.
Crushing caused by unintentional activation
There is a risk of injury if the drive system is activated
unintentionally.
Remove the battery if the battery is not absolutely
necessary for assembly.
Assemble the bicycle in a clean and dry environment.
The working environment temperature should be
between 15 °C and 25 °C.
Working environment temperature 15 °C–25 °C
Table 23: Working environment temperature
CAUTION
!
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Transportation, storage and assembly
5.3.2 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.
5.3.3 Scope of delivery
The bicycle was completely assembled in the factory
for test purposes and then dismantled for
transportation.
The bicycle is 95–98% pre-assembled. The scope of
delivery includes:
the pre-assembled bicycle
the front wheel
the pedals
quick release (optional)
the charger
the operating instructions.
The battery is supplied separately from the bicycle.
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
!
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5.3.4 Commissioning
Since initial commissioning of the bicycle requires
special tools and specialist knowledge, only trained
specialist staff may perform initial commissioning.
Experience has shown that a bicycle which has not yet
been sold, is spontaneously handed to consumers as
soon as it appears ready to ride.
For this reason, every bicycle must be prepared, so
that it is fully ready for use immediately after being
assembled.
Staff should work through the initial commissioning
check list to prepare the bicycle, so that it is ready
to ride.
Fire and explosion caused by incorrect charger
Batteries which are charged with an unsuitable
charger, may become internally damaged. This may
result in fire or an explosion.
Only ever use the battery with the supplied charger.
Mark the supplied charger and these operating
instructions clearly to prevent mix-ups – with the
bicycle 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
!
CAUTION
!
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Initial commissioning check list
Check the battery
The battery is supplied partially charged. Fully charge the
battery to ensure full power
Mount the wheels, quick release and pedals.
Re-adjust the quick release clamping force if necessary.
Thoroughly degrease the brake discs in disc brakes or the brake
sides and linings in rim brakes with brake cleaner or spirit.
Place handlebars, stem and saddle in the functional position
and check they are firmly in place.
Check all the components to make sure that they are firmly in
place. Check all the settings and the tightening torque on the
axle nuts.
Check the entire cable harness to make sure that it is routed
properly:
You must prevent the cable harness from coming into
contact with moving parts.
The cable routes must be smooth and free from sharp edges.
Moving parts must not apply any pressure or tension to the
cable harness.
Check the drive system, the light equipment and the brakes to
make sure that they are fully functional and effective.
Adjust the headlight.
Set the drive system has to the national language and the
appropriate system of measurement.
Check the software version of the drive system and update it as
necessary.
Take a test drive to check the brake system, gear shift and the
electric drive system.
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5.3.4.1 Checking the battery
The battery needs to be checked before it is charged
for the first time.
Press the On-Off button (battery).
If none of the LEDs on the operating and charge
status indicator light up, the battery may be
damaged.
The battery can be charged if at least one of the
LEDs on the operating and charge status indicator
is fully lit up, but not if all of them are.
Once the battery has been charged, insert the
battery on the bicycle.
Risk of fire and explosion due to faulty battery
The safety electronics on damaged or faulty batteries
may fail. The residual voltage can cause a short
circuit. The batteries may self-ignite and explode.
Never charge a defective battery.
WARNING
!
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5.3.5 Mounting the wheel in the Suntour fork
Alternative
5.3.5.1 Mounting the wheel with screw-on axle (15 mm)
Alternative
Insert the axle completely on the drive side.
Figure 16: Fully inserting the axle
Tighten the axle with a 5 mm hexagon socket
spanner to 8–10 Nm.
Figure 17: Tightening the axle
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Insert the securing screw on the non-drive side.
Figure 18: 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 19: Tightening the securing screw
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5.3.5.2 Mounting the wheel with screw-on axle (20 mm)
Alternative
Insert the axle completely on the drive side.
Figure 20: Tightening the inserted axle
Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 21: Tightening the axle
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5.3.5.3 Mounting the wheel with a quick release axle
Alternative
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 result in a crash and 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 result in a crash and
injuries.
Never fasten a quick release axle with a tool, such
as a hammer or pliers.
CAUTION
!
CAUTION
!
CAUTION
!
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Insert the axle into the hub on the drive side.
Clamping version II.
Figure 22: Pushing the axle into the hub
Tighten the axle with the red handle.
Figure 23: Tightening the axle
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Push the quick release lever into the axle.
Figure 24: Pushing the quick release lever into the axle
Reverse the quick release lever.
The lever is secured.
Figure 25: Securing the lever
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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 26: 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 27: Adjusting the quick release clamping force
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5.3.6 Mounting the wheel with a quick release
Alternative
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 result
in a crash and 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 result in a crash and
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
!
CAUTION
!
CAUTION
!
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Before mounting, ensure that the quick release
flange is extended. Open the lever completely.
Figure 28: Open and closed flange
Push in the quick release until you hear a clicking
sound. Make sure that the flange is extended.
Figure 29: Pushing the quick release in
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Adjust the clamping with a half-open clamping lever
until the flange reaches the fork end.
Figure 30: 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 31: Closing the quick release
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5.3.7 Mounting the wheel in the FOX fork
Alternative
5.3.7.1 Mounting the wheel with the quick release (15 mm)
Alternative
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 32: 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. The lever must be
tensioned to the point that it leaves a mark on your
hand.
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The lever must be 1 to 20 mm ahead of the fork leg
in the closed position.
Figure 33: 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.
5.3.7.2 Adjusting the FOX quick release
Figure 34: 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
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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.
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5.3.7.3 Mounting the wheel with Kabolt axles
Alternative
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 35: Pushing the Kabolt axle in
Tighten the Kabolt axle screw to 17 Nm (150 in-lb)
with a 6 mm hex key.
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5.3.7.4 Checking the stem and handlebars
Checking connections
Stand in front of the bicycle to check whether the
handlebars, stem and fork shaft 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.
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 shaft.
If the handlebars shaft should move in the fork
shaft, 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.
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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 bicycle 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.
5.3.8 Sale of the bicycle
Fill out the data sheet on the first page of the
operating instructions.
Adjust the bicycle to the rider.
Set the stand and the shifter, and show the
purchaser the settings.
Instruct the operator or rider how to use all the
functions of the bicycle.
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Before the first ride
6 Before the first ride
Only a correctly adjusted bicycle 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.
6.1 Adjusting the saddle
6.1.1 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.
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
result in a crash and injuries.
Always observe the indicated torques on the screw
or in the operating instructions.
CAUTION
!
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Place the saddle tilt in the horizontal position to
adjust the bicycle to your needs for the first time.
Figure 36: Horizontal saddle tilt
6.1.2 Determining the seat height
To determine the seat height safely, either push the
bicycle near to a wall, so that you can lean on the wall
to support yourself or ask another person to hold the
bicycle 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.
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Before the first ride
Figure 37: Optimal saddle height
6.1.3 Adjusting the seat height with quick release
Open the quick release on the seat post to change
the seat height. To do so, pull the clamping lever
away from the seat post.
Figure 38: Seat post quick release (3) with clamping lever (5) and setting
bolt (4) in the open position (1) and in the direction of the closed
position (2)
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Set the seat post at the required height.
Figure 39: 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 the quick releases.
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 result in a crash and
injuries.
Do not pull the seat post out of the frame beyond
the minimum insertion depth marking.
CAUTION
!
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Before the first ride
6.1.4 Setting the height-adjustable seat post
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 40: The seat post activation lever can be mounted either on the left (1)
or the right (2) side of the handlebars
6.1.4.1 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.
6.1.4.2 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.
.
ert wer
e Position zur Best
ber in einem späteren
chmals montieren.
ie den mitgelieferten Winkel mit der in
rrichtung und stecken Sie die Hülle in die
vorrichtung.
er
Remotehebel
5
Oder
28
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6.1.5 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
bicycle near to a wall, so that you can lean on the wall
to support yourself or ask another person to hold the
bicycle 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 within its
permitted displacement range only (marked on the
saddle stay).
Figure 41: Knee cap perpendicular line
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Before the first ride
6.2 Adjusting the handlebars
Adjusting the stem
The handlebars must only be adjusted while the
bicycle is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the maximum
tightening torque for the clamping screws of the
handlebars.
Maximum tightening torque for the
clamping screws of the handlebars*
*if there is no other data on the component
5Nm - 7Nm
Table 24: Handlebars clamping screw maximum tightening torque
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 result in a crash and
injuries.
Check the handlebars and the quick release system
are firmly in position after the first two hours of
riding.
CAUTION
!
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6.2.1 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 42: Open (2) and closed (1) clamping lever on the stem; by.schulz
speedlifter used as an example
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
result in a crash and 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
!
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Before the first ride
6.2.2 Turning the handlebars to the side
Alternative
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.
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 result in a crash and
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
!
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Figure 43: Pulling locking lever upwards; by.schulz speedlifter used as an
example
6.2.2.1 Checking the clamping force of the 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.
6.2.2.2 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.
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Before the first ride
6.3 Adjusting the brake lever
6.3.1 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.
Figure 44: Using the twist knob (1) to adjust the pressure point
Brake failure due to incorrect setting
If the pressure point is set with brakes where the brake
lining 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 lining and brake disc have not reached their
wear limit.
WARNING
!
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6.3.2 Adjusting the grip distance
Figure 45: Brake lever grip distance
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 you to fall from the bicycle and injure
yourself.
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
!
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Before the first ride
6.3.2.1 Adjusting the grip distance on a Magura brake lever
Alternative
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 46: Using the setting screw (2) to adjust the distance from the brake
lever to the handlebar grip (1)
1
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6.4 Adjusting the suspension of the Suntour
fork
Alternative
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.
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
Table 25: 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 result in a crash and injuries.
Never ride the bicycle without air in the air
suspension fork.
Never use the bicycle without adjusting the
suspension fork to the rider's weight.
Settings on the chassis change riding performance
significantly. You need to get used to the bicycle
and break it in to prevent accidents.
CAUTION
!
NOTICE
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Before the first ride
6.4.1 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.
"SAG" depends on the rider's position and weight and
should be between 15% and 30% of the maximum fork
deflection, depending on bicycle usage and
preferences.
6.4.1.1 Adjusting the air suspension fork negative deflection
Alternative
The air valve is located under a cover on the head
of the left shock absorber. Screw off the cover.
Figure 47: 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.
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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 a temporarily attached cable tie downward
against the dust wiper of the fork.
Put on your usual bicycling clothing, including
luggage.
Sit on the bicycle in your usual riding position and
support yourself (e.g. against a wall or tree).
Get off the bicycle 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."
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 26: Filling pressure pump of the Suntour air forks
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Before the first ride
Once the "SAG" is correct, re-tighten the blue air
cover cap clockwise.
6.4.1.2 Adjusting the steel suspension fork negative
deflection
Alternative
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 bicycle.
Figure 48: 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.
If you cannot achieve the desired "SAG", you may
need to make an internal adjustment. For this purpose,
contact your specialist dealer.
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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.
6.4.2 Adjusting the rebound
Alternative
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 49: 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.
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Before the first ride
6.4.3 Setting the compression
Alternative
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 50: Suntour compression adjuster with the OPEN (1) and LOCK(2)
positions
Compression damping is lowest in the OPEN position,
making the fork feel softer. Use the LOCK position if
you want the fork to feel stiffer and you are riding on
soft ground. The lever positions between the OPEN
and LOCK positions enable fine adjustment of
compression damping.
We recommend setting the lever of the compression
adjuster to the OPEN position first.
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6.5 Adjusting the suspension of the FOX fork
Alternative
The adjustment shown here represents a basic
setting. The rider should change the basic setting to
suit the surface and his/her preferences.
It is advisable to make a note of the basic setting.
This way, it can be used as the starting point for
subsequent, optimised settings and to safeguard
against unintentional changes.
6.5.1 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. "SAG"
depends on the rider's position and weight and should
be between 15% and 20% of the maximum fork
deflection, depending on bicycle usage and
preferences.
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 result in a crash and injuries.
Never ride the bicycle without air in the air
suspension fork.
Never use the bicycle without adjusting the
suspension fork to the rider's weight.
Settings on the chassis change riding performance
significantly. You need to get used to the bicycle and
break it in to prevent accidents.
CAUTION
!
NOTICE
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Before the first ride
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.
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.
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 27: Filling pressure table of the FOX air fork
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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 bicycle in your usual riding position and
support yourself (e.g. against a wall or tree).
Get off the bicycle 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.
If you cannot achieve the desired "SAG", you may
need to make an internal adjustment. For this purpose,
contact your specialist dealer.
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Before the first ride
6.5.2 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 51: 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.
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6.5.3 Setting the compression
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 52: 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 compression
adjuster to the OPEN mode position first.
1
2
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Before the first ride
6.6 Adjusting the rear frame damper
Alternative
6.6.1 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. "SAG" depends on the rider's position and
weight and should be between 25% and 30% of the
maximum rear frame damper deflection, depending on
bicycle 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.
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.
NOTICE
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Figure 53: 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 bicycle in your usual riding
position and support yourself, e.g. against a wall or
tree.
Push the O-ring (4) downward against the rubber
air chamber seal (1).
Get off the bicycle 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."
25-30%
2
1
3
4
5
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Before the first ride
6.6.2 Setting the compression
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 54: 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 uneven terrain and the HARD
position for efficient climbing. First set the
compression adjuster to the OPEN position.
Figure 55: Fine adjustment of the OPEN position is made using the
adjuster (4)
1
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The FOX rear frame damper features fine adjustment
for the OPEN position.
We recommend that these 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.
6.6.3 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 56: FOX rebound adjuster (1) on the rear frame damper
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Before the first ride
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.
6.7 Retracting brake linings
New brake linings take time to break in and adjust to
their final braking force.
Accelerate bicycle to about 25 km/h.
Brake bicycle 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 28: Filling pressure table of the FOX air fork
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7 Operation
Crash caused by loose clothing
Laces, scarves and other loose items may become
entangled in the spokes on the wheels and the chain
drive. This may cause you to fall from the bicycle and
injure yourself.
Wear sturdy footwear and close-fitting clothing.
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 bicycle on a flammable surface
(grass, wood, etc.) directly after use.
Crash caused by soiling
Heavy soiling can impair the functions of the bicycle,
for example, the function of the brakes. This may
cause you to fall from the bicycle and injure yourself.
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.
When riding downhill, high speeds may be reached.
The bicycle is only engineered for exceeding a speed
of 25 km/h briefly. In particular the tyres can fail if
exposed to a continuous load.
Decelerate the bicycle with the brakes if higher
speeds than 25 km/h are reached.
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
NOTICE
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Operation
You can be ride the bicycle within a temperature range
between 5 °C and 35 °C. The effectiveness of the
drive system is restricted outside of this temperature
range.
Moisture penetrating at low temperatures may impair
individual bicycle functions due to the open structural
design.
Always keep the bicycle dry and free from frost.
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 condition of the roads.
Heat or direct sunlight can cause the tyre pressure to
increase above the permitted maximum pressure. This
can destroy the tyres.
Never park the bicycle in the sun.
On hot days, regularly check the tyre pressure and
adjust it as necessary.
NOTICE
Operation temperature 5 °C–35 °C
If the bicycle is to be used at temperatures below
3 °C, the specialist dealer must carry out an
inspection and prepare the bicycle for winter usage
first.
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7.1 Before each ride
Crash caused by difficult-to-spot damage
If the bicycle 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 you to fall from the bicycle
and injure yourself.
Take the bicycle 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 you to fall from the bicycle and injure yourself.
Remove the bicycle from service immediately in
case of 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 inspects the bicycle 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 to strong heat sources.
CAUTION
!
CAUTION
!
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Operation
7.2 Check list before each ride
Check the bicycle before each ride.
Do not use the bicycle if there are any anomalies.
Check that the bicycle is complete.
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 bicycle has been transported or secured with a
lock.
Check the valves and the tyre pressure. Adjust as necessary
before each ride.
If the bicycle has a hydraulic rim brake, check whether the
locking levers are fully closed in their final positions.
Check the front and rear wheel brakes to make sure that they
are working properly. To do so, operate the brake levers while
stationary in order to check whether resistance is generated in
the usual brake lever position. The brake must not lose any
brake fluid.
Check that the driving 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 bicycle's lower
surfaces.
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.
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7.3 Using the kickstand
Raising the kickstand
Before the ride, raise the kickstand completely with
your foot.
Parking the bicycle
Before parking, lower the kickstand completely with
your foot.
Park the bicycle carefully and check that it is stable.
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 the ride.
The heavy weight of the bicycle may cause the
kickstand to sink into soft ground and the bicycle may
topple and crash over.
The bicycle must be parked on firm, level ground
only.
It is particularly important to check that the bicycle
is stable if it is equipped with accessories or loaded
with luggage.
CAUTION
!
NOTICE
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Operation
7.4 Using the pannier rack
Crash caused by loaded pannier rack
The riding performance of the bicycle changes with a
loaded pannier rack, in particular when steering and
braking. This can lead to a loss of control. This may
cause you to fall from the bicycle and injure yourself.
You should practice how to use a loaded pannier
rack safely and reliably before using the bicycle in
public spaces.
Crash caused by unsecured luggage
Loose or unsecured objects on the pannier rack, e.g.
belts, may become caught in the rear wheel. This may
cause you to fall from the bicycle and injure yourself.
Objects which are fastened to the pannier rack may
cover the bicycle's reflectors and the driving light. The
bicycle may be overseen on public roads. This may
cause you to fall from the bicycle and injure yourself.
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.
CAUTION
!
CAUTION
!
CAUTION
!
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Distribute the luggage as evenly as possible on the
left and right-hand side of the bicycle.
We recommend the use of panniers and luggage
baskets.
The maximum load bearing capacity is indicated on the
pannier rack.
Never exceed the permitted total weight when
packing the bicycle.
Never exceed the maximum load bearing capacity
of the pannier rack.
Never modify the pannier rack.
NOTICE
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Operation
7.5 Rechargeable battery
Fire and explosion due to defective 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.
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.
Chemical burns to the skin and eyes caused by
faulty battery
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
!
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Before the battery is removed or inserted, switch off
the battery and the drive system.
Risk of fire and explosion due to high temperatures
Excessively high temperatures will damage the
battery. The battery may self-ignite and explode.
Never expose the battery to sustained direct
sunlight.
Fire and explosion caused by 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.
Fire and explosion caused by 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.
If a key is left inserted when transporting the bicycle or
when riding, it may break off or the lock 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
!
CAUTION
!
CAUTION
!
NOTICE
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Operation
7.5.1 Removing the battery
Open the battery lock with the key.
The battery is released and falls into the retainer
guard.
Hold the battery in your hand from below. Use the
other hand to push on the retainer guard from
above.
The battery is released and falls into the hand.
Remove the battery from the frame.
Remove the key from the lock.
7.5.2 Inserting the battery
Place the battery with the contacts first into the
lower mount.
Flip the battery up so that it is held by the retainer
guard.
Push the battery upwards so that it audibly clicks
into place.
Check the battery to make sure it is firmly in place.
Lock the battery with the key. Otherwise the battery
may fall out of the mount when you open the lock.
Remove the key from the lock.
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7.5.3 Charging the 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.
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.
Risk of fire and explosion caused by damaged
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.
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 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
!
CAUTION
!
CAUTION
!
CAUTION
!
NOTICE
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Operation
The ambient temperature during the charging
process must be within the range from 10 °C to
30 °C.
The battery can remain on the bicycle or be removed
for charging.
Interrupting the charging process does not damage
the 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.
During the charging process the operating and
charge status indicator indicates the charge status.
When the drive system is switched on, the display
shows the charging process.
The charging process is complete when the LEDs
of the operating and charge status indicator go out.
7.5.4 Waking the battery
When not used for a longer period, the battery
switches to sleep mode for self-protection. The LEDs
of the operating and charge status indicator do not
light up.
Press the On-Off button (battery).
The battery's operating and charge status indicator
indicates the charge status.
Charging temperature 10 °C–30 °C
Connection data 230 V, 50 Hz
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7.6 Electric drive system
7.6.1 Switching on the drive system
A sufficiently charged battery has been inserted on the
bicycle.
The battery is firmly positioned. The key has been
removed.
Press the On-Off button (battery).
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force.
7.6.2 Activating the standby mode
If the bicycle is not moved, the display unit and motor
will switch to standby mode. This can also be activated
manually. As soon as you move the bicycle again, the
display and motor are activated again and the electric
drive system is once again available. After two hours
in standby, the battery will switch to deep sleep mode.
If you wish to switch your bicycle off for a short time,
you can switch it to standby as follows:
Briefly press the On-Off button (operating
element).
The battery remains in standby mode for 2 hours.
Crash caused by lack of readiness for braking
When it is switched on, the drive system can be
activated by the application of force on the pedals.
There is a risk of a crash if the drive is activated
unintentionally, and the brake is not reached.
Never start the electric drive system, or switch it off
immediately, if the brake cannot be reached safely
and reliably.
CAUTION
!
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Operation
7.6.3 Switching off the drive system
The system switches off automatically ten minutes
after the last command. The following options are
available to manually switch off the drive system.
Press the On-Off button (operating element) for
>3 sec.
or
Press the On-Off button (battery) for >3 sec.
The display, operating element, motor and battery
will be switched off completely.
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7.7 Electric drive system
7.7.1 Switching on the drive system
A sufficiently charged battery has been inserted on the
bicycle.
The battery is firmly positioned. The key has been
removed.
Press the On-Off button (operating element).
or
Press the On-Off button (battery).
The indicator will switch on after a few seconds.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force.
7.7.2 Waking the drive system
The system switches off automatically several minutes
after the last command. The following options are
available to manually switch off the drive system.
Press the On-Off button (operating element).
The drive system switches on again.
Crash caused by lack of readiness for braking
When it is switched on, the drive system can be
activated by the application of force on the pedals.
There is a risk of a crash if the drive is activated
unintentionally, and the brake is not reached.
Never start the electric drive system, or switch it off
immediately, if the brake cannot be reached safely
and reliably.
CAUTION
!
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Operation
7.7.3 Switching off the drive system
The system switches off automatically several minutes
after the last command. The following options are
available to manually switch off the drive system.
Press the On-Off button (operating element).
or
Press the On-Off button (battery).
The display and LEDs on the charge status
indicator disappear.
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7.8 Control panel with display
7.8.1 Removing and attaching the display
Attaching the display
Place the display tilted to the left on the mount.
Turn the display 45° clockwise.
Connect the display to the motor via the intermediate
cable.
.
Figure 57: Attaching the display
If the rider is not present, the display can be used
without authorisation, e.g. it may be stolen, the system
settings may be changed or journey information may
be read.
Remove the display when the bicycle is parked.
NOTICE
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Operation
Removing the display
Disconnect the display from the intermediate cable.
Turn the display 45° anticlockwise.
Remove the display from above.
.
Figure 58: Removing the display
1Display
2 Rotation direction of the display
3 Mount
7.8.2 Using the driving light
To switch on the driving light, the drive system has to
be switched on already.
Press the headlight button briefly.
The driving light is switched on, and the driving light
symbol is displayed.
Press the headlight button briefly again.
The running light is switched off, and the driving light
symbol is not displayed.
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7.8.3 Using the push assist system
The push assist helps the rider to push the bicycle.
The maximum speed can be 6 km/h here.
Press and hold the push assist button for longer
than three seconds.
The push assist is activated. The push assist symbol
is displayed.
Release the push assist button to shut off the push
assist.
Fall caused by strong acceleration
If the pedals are pressed with the push assist
activated, the bicycle accelerates rapidly. This may
cause you to fall from the bicycle and injure yourself.
Never mount the bicycle with the push assist
activated.
The pedals turn when using the push assist due to the
system design.
You must steer the bicycle securely with both hands
when using push assist.
Allow for enough freedom of movement for the
pedals.
Never use a push assist for slow riding.
CAUTION
!
NOTICE
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Operation
7.8.4 Selecting the level of assistance
Press the plus button.
The level of assistance is increased.
Press the minus button.
The level of assistance is reduced.
7.8.5 Switching the journey information
The displayed journey information can be changed and
partially reset.
Press the info button repeatedly until the journey
information is displayed.
7.8.6 Using the USB port
The USB port can be used to operate external devices
which can be connected using a standard micro A/
micro B USB 2.0 cable.
The display has been inserted correctly into the
mount.
Open the protective flap on the USB port.
Using a suitable USB cable, connect the USB
interface and the desired end device.
The display "CHArG" will appear briefly on the
display.
Replace the protective flap after using the USB
port.
Any moisture which enters through the USB port may
trigger a short circuit in the display.
Regularly check the position of the rubber cover on
the USB port and adjust it as necessary.
NOTICE
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7.8.7 Changing the system information
The following system settings can be changed:
Press and hold the headlight button for three
seconds.
Press the info button repeatedly until the journey
information is displayed.
Change values by pressing the minus and plus
buttons.
When the values are correct, press the info button
briefly.
Press and hold the headlight button for three
seconds.
The journey information is displayed again.
Screen display Function
RESET TRIP Set trip time, calories burned, distance
and average speed to 0
RESET ALL Set all values incl. total distance and total
trip time to 0
DAT E DD/MM/YY
TIM E F OR M AT 24/12
TIM E hh/mm
LANGUAGE German/English
METRIC/IMPERIAL km/mi
Table 29: Changeable system settings
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Operation
7.9 Control panel with display
7.9.1 Using the driving light
To switch on the driving light, the drive system has to
be switched on already.
Press the headlight button.
The driving light is switched on. The display
backlight is switched on.
Press the headlight button again.
The driving light is switched off. The display
backlight is switched off.
7.9.2 Using the push assist system
The push assist helps the rider to push the bicycle.
The speed can be a maximum of 6 km/h in this case.
The tractive power of the push assist and its speed
can be influenced by the selection of gear. To spare
the drive, first gear is recommended for travelling
uphill.
Press and hold the plus button.
Injury from pedals or wheels
The pedals and the drive wheel turn when the push
assist system is used. There is a risk of injury if the
bicycle wheels are not in contact with the ground when
the push assist system is used (e.g. when carrying the
bicycle up stairs or when loading a bike rack).
Only use the push assist mode when pushing the
bicycle.
You must steer the bicycle securely with both hands
when using push assist.
Allow for enough freedom of movement for the
pedals.
CAUTION
!
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The push assist system is activated.
Release the plus button to shut off the push assist.
The push assist system switches off automatically
as soon as the bicycle pedals are operated or the
speed exceeds 6 km.
7.9.3 Selecting the level of assistance
Press the plus button.
The level of assistance is increased.
Press the minus button.
The level of assistance is reduced.
7.9.4 Changing the kilometre display unit
Press and hold the settings button.
The kilometre display unit changes between metric
units of measure (km/h) and imperial units of measure
(mph).
7.9.5 Switching journey information
The display shows three pieces of journey information:
The standard setting for the display is the trip distance
(TRP).
The displayed journey information can be changed and
partially reset.
Press the settings button.
The remaining bicycle range (R) is shown.
Press the settings button again.
Screen display Function
TRP Trip distance
RRemaining bicycle range
TTotal trip distance completed by bicycle
Table 30: Journey information
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Operation
Total trip distance (T) completed by bicycle is
shown.
Press the settings button again.
The trip distance (TRP) is shown.
7.9.5.1 Deleting trip distance
Press and hold the minus button.
The trip distance is reset to 0 km.
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7.10 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.
7.10.1 Selecting gears
The speed and range can be increased while applying
the same force if you select the right gear. A gear
recommendation is shown on the display to help you
select.
Figure 59: Display with high (2) and low (1) gear recommendation
If the gear recommendation is shown high, you
should shift to a higher gear with a lower pedalling
frequency.
If the gear recommendation is shown low, you
should shift to a lower gear with a higher pedalling
frequency.
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Operation
7.10.2 Using the derailleur gears
Alternative
Figure 60: Down shifter (1) and up shifter (2) on the left (I) and right (II) 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.
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7.10.3 Using a hub gear
Alternative
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. The bicycle may flip over or fall, which
may cause injuries.
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.
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 bicycle 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
!
NOTICE
NOTICE
NOTICE
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Operation
.
Figure 61: 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.
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7.11 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.
DANGER
!
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Operation
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.
After ingestion
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.
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 disc brake openings.
Always keep fingers well away from the rotating
brake disc.
WARNING
!
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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 as a consequence.
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.
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.
WARNING
!
CAUTION
!
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Operation
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 back and down as far as
possible.
Practise braking and emergency braking before the
bicycle is used in public spaces.
Never use the bicycle if you can feel no resistance
when pulling on the brake handle. Consult a
specialist dealer.
Crash after cleaning or storage
The brake system is not designed for use on a bicycle
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 bicycle is placed on its side or turned upside
down, apply the brake a couple of times before
setting off to ensure that it functions normally.
Never use the bicycle if it no longer brakes as
normal. 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.
CAUTION
!
CAUTION
!
CAUTION
!
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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.
7.11.1 Using the brake lever
Figure 62: Front (2) and rear (1) brake lever; Shimano brake used as an
example
Pull the left brake lever for the front wheel brake and
the right lever for the rear wheel brake until the
desired speed is reached.
7.11.2 Using the back-pedal brake
Alternative
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.
1
2
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Operation
7.12 Suspension and damping
7.12.1 Adjusting the compression of the Suntour fork
Alternative
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 63: Suntour compression adjuster with the OPEN (1) and LOCK(2)
positions
Compression damping is lowest in the OPEN
position, making the fork feel softer. Use the LOCK
position if you want the fork to feel stiffer and you
are riding on soft ground. The lever positions
between the OPEN and LOCK positions enable fine
adjustment of compression damping.
We recommend setting the lever of the compression
adjuster to the OPEN position first.
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7.12.2 Adjusting the compression of the Fox fork
Alternative
The compression adjuster makes it possible to make
quick adjustments to the suspension behaviour of the
fork to suit changes in terrain. It is intended for
adjustments made during the ride.
Figure 64: 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 compression
adjuster to the OPEN mode position first.
1
2
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Operation
7.12.3 Adjusting the compression of the Fox fork
Alternative
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 65: 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 uneven terrain and the HARD
position for efficient climbing. First set the
compression adjuster to the OPEN position.
Figure 66: Fine adjustment of the OPEN position is made using the
adjuster (4)
1
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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.
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Maintenance
8 Maintenance
Cleaning check list
Maintenance check list
Clean pedals after each ride
Clean suspension fork and, if necessary, rear
frame damper after each ride
Clean 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 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 the 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 the chain tension once a month
Check the 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 they are
fully functional
every three
months
Check for wear on brake discs at least every six
months
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Service check list
Functional check on the suspension fork every 50 hours
Suspension fork maintenance and
dismantling
every 100 hours or at
least once a year
Complete maintenance of the rear frame
damper every 125 hours
Inspection by the specialist dealer every six months
Inspection of the drive unit 15,000 km
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Maintenance
8.1 Cleaning and servicing
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.
8.1.1 After each ride
8.1.1.1 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.
8.1.1.2 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.
8.1.1.3 Cleaning the pedals
Clean with a brush and soapy water after riding
through dirt or rain.
Service the pedals after cleaning.
Crash and falling caused by unintentional activation
There is a risk of injury if the drive system is activated
unintentionally.
Remove before cleaning.
CAUTION
!
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8.1.2 Basic cleaning
Remove battery and display before basic cleaning.
Crash caused by brake failure
The braking effect may be unusually poor temporarily
after cleaning, servicing or repairing the bicycle. This
may cause you to fall from the bicycle and injure
yourself.
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.
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 bicycle 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.
CAUTION
!
NOTICE
NOTICE
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Maintenance
8.1.2.1 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.
8.1.2.2 Cleaning the stem
Clean stem with a cloth and washing water.
Service the stem after cleaning.
8.1.2.3 Cleaning the rear frame damper
Clean rear frame damper with a cloth and washing
water.
8.1.2.4 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 braking hard on rims
A rim can break and block the wheel if you brake hard.
It may cause a crash with serious injuries.
Check rim wear on a regular basis.
WARNING
!
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8.1.2.5 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.
8.1.2.6 Cleaning the chain
Slightly dampen a brush with dish-washing liquid.
Brush both sides of the chain.
Dampen a cloth with dish-washing liquid. Place the
cloth on the chain.
Hold with 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
WD40.
Service the chain after cleaning.
Never use aggressive (acid-based) cleaners, rust
removers or degreasers when cleaning the chain.
Do not use chain cleaning devices or chain cleaning
baths.
NOTICE
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Maintenance
8.1.2.7 Cleaning battery
Clean the battery electrical connections with a dry
cloth or brush only.
Wipe off the decorative sides with a damp cloth.
8.1.2.8 Cleaning the display
Carefully clean the display with a damp, soft cloth.
Fire and explosion caused by 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.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the bicycle before
cleaning.
CAUTION
!
If water enters into the display, 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 bicycle before
cleaning.
NOTICE
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8.1.2.9 Cleaning the drive unit
Carefully clean the drive unit with a damp, soft
cloth.
8.1.2.10 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.
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.
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
!
NOTICE
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 bicycle with a high-pressure water
device or compressed air.
Take great care when using a hosepipe. Never
point the water jet directly at the seal section.
WARNING
!
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Maintenance
8.1.3 Servicing
8.1.3.1 Servicing the frame
Dry frame after cleaning
Spray with care oil Clean off the care oil again after
a short time.
8.1.3.2 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.
8.1.3.3 Servicing the fork
Treat the dust seals with fork oil
8.1.3.4 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.
8.1.3.5 Servicing the pedal
Treat with spray oil after cleaning.
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8.1.3.6 Servicing the chain
Grease the chain thoroughly with chain oil after
cleaning.
8.1.3.7 Servicing the drive elements
Service front and rear derailleur articulated shafts
and jockey wheels with Teflon spray.
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Maintenance
8.2 Maintenance
The following maintenance measures must be carried
out regularly [Check list, page 139]. They can be
carried out by the operator and rider. In case of any
doubt, consult the specialist dealer.
8.2.1 Wheel
Check the 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.
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.
CAUTION
!
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake hard.
It may cause a crash with serious injuries.
Check rim wear on a regular basis.
If the 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 pressure in the tyre is too high, the tyre may
burst.
Check the tyre pressure against the specifications
[Data sheet, page 1]
Adjust the tyre pressure as necessary.
WARNING
!
NOTICE
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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.
8.2.2 Brake system
Replace the brake linings on the disc brake when
the pad thickness has reached 0.5 mm.
8.2.3 Electrical cables and brake cables
Check all visible electrical cables and cables for
damage. If, for example, the sheathing is
compressed, the bicycle 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.
8.2.4 Gear shift
Check the gear shift and the shifter or the twist grip
setting and adjust it as necessary.
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 you to fall from the bicycle and
injure yourself.
Check the brake disc, brake linings and the
hydraulic brake system on a regular basis and
replace if necessary.
CAUTION
!
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Maintenance
8.2.5 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 the
instructions.
Check for wear and signs of corrosion (maintain
with an oily cloth) and for oil leaks.
8.2.6 Checking the chain and belt tension
Check the chain or belt tension in three or four
positions, turning the crank a full revolution.
The ideal chain or belt tension has been achieved
if the chain or the 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.
Excessive chain or belt tension increases wear.
If the chain or belt tension is too low, there is a risk that
the chain or belt will slip off the chain wheels.
Check the chain or belt tension once a month.
NOTICE
If the chain or the belt can be pushed more than
2 cm, you need to have the chain or belt tensioned
again by the specialist dealer.
If the chain or belt can only be pushed up and down
less than 1 cm, you will need to slacken the chain or
belt slightly.
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Figure 67: Checking the chain and belt tension
8.2.7 USB port
8.2.8 Suspension fork
If a hub gear is featured, the rear wheel must be
pushed backwards or forwards to tighten the chain.
This should be done by a specialist only.
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.
The specialist dealer will check the suspension fork
function and the torques of attachment screws and
nuts on the lower surfaces (steel: 10 Nm; alloy:
4 Nm). They will check the suspension fork for
scratches, dents, cracks, stains, oil leaks or signs of
wear or corrosion.
NOTICE
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Maintenance
8.3 Service
The specialist dealer must perform an inspection at
least every six months. This is the only way to ensure
that the bicycle remains safe and fully functional.
After a mileage of 15,000 km, the drive belt must be
replaced by the BMZ-certified service centre.
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 you to
fall from the bicycle and injure yourself.
Have the specialist dealer carry out six-monthly
basic cleaning of the bicycle, preferably at the same
time as the required servicing work.
The motor is maintenance-free and may only be
opened by qualified specialist personnel.
Never open the motor.
The specialist dealer will inspect the bicycle 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.
CAUTION
!
CAUTION
!
NOTICE
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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).
The specialist dealer will fully inspect the interior
and exterior of the rear frame damper, overhaul the
rear frame damper, replace all air seals of air forks,
overhaul the air suspension, change the oil and
replace the dust wipers.
The further servicing measures correspond to those
which are recommended for a bicycle as per
EN 4210. Particular attention is paid to the rim and
brake wear. The spokes are re-tightened in
accordance with the findings.
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Maintenance
8.4 Adjusting and repairing
8.4.1 Use original parts and lubricants only
The individual parts of the bicycle have been selected
carefully and to matched to each other.
Only original parts and lubricants must be used for
maintenance and repair.
The constantly updated lists of approved accessories
and parts are available to specialist dealers.
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.
CAUTION
!
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8.4.2 Wheel quick release
Crash caused by unfastened quick release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the wheel.
This will cause a crash.
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 result
in a crash and 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 result in a crash and
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
!
CAUTION
!
CAUTION
!
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Maintenance
8.4.2.1 Clamping the clamping lever
The clamping lever for the quick release is marked
OPEN and CLOSE. If you can read the word OPEN,
the quick release is open. If you can read the word
CLOSE, the quick release is clamped.
Align the clamping lever properly and push it
through as far as it will go.
The wheel clamping lever is clamped 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.
8.4.2.2 Clamping version I
Hold the open clamping lever. Screw the setting nut
tight on the opposite side.
Clamp the clamping lever.
The final position of the clamping lever is at a right
angle to the fork or frame.
Figure 68: Wheel quick release, version I, with clamping lever (2), fork (1) and
setting nut (3)
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Checking and setting the clamping force of the
quick releases
If the clamping lever cannot be moved into the final
position just by pushing it with the hand, or if it is too
loose, its clamping force will need to be readjusted.
The clamping lever is completely open.
Turn the setting nut a little.
Clamp the clamping lever.
Repeat the steps until the proper angle has been
achieved.
8.4.2.3 Clamping version II
Figure 69: Quick release, version II, with clamping lever (1), axle (2), setting
nut (3), and detailed view of the open (4) and closed (5) flange
The clamping lever is completely open.
Push the axle into the hub as far as it will go.
Align the clamping lever.
Close the clamping lever
The final position of the clamping lever is forward,
parallel to the fork.
1
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Maintenance
8.4.2.4 Clamping version III
Figure 70: Quick release, version III, with axle (1) and clamping lever (2)
Push the axle into the hub as far as it will go with
the clamping lever completely open.
Screw the quick release on the open clamping lever
clockwise into the hub as far as it will go.
Screw it out one turn.
Use the fingers to screw in the clamping lever in the
semi-open position, roughly in the middle between
OPEN and CLOSE, until you feel resistance.
Clamp the clamping lever.
If the clamping force is insufficient, have the specialist
dealer inspect it.
NOTICE
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8.4.2.5 Clamping version IV
Push the axle into the hub as far as it will go with
the clamping lever open.
Screw the clamping lever clockwise into the correct
final position.
Clamp the clamping lever.
Setting the clamping force
If the clamping force is set too high, the clamping lever
cannot be pushed into the closed final position.
Turn the twist knob:
Turn 1/8 turn anti-clockwise to reduce the clamping
force.
Turn 1/8 turn clockwise to increase the clamping force.
Clamp the clamping lever.
If the clamping lever is not yet in the proper final
position, repeat the steps until the proper final
position has been achieved.
Figure 71: Wheel quick release, version IV, with twist knob (1) and clamping
lever (2)
2
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Maintenance
8.4.2.6 Clamping version V
Push the axle into the hub from the left until it
meshes in the thread on the right-hand fork end.
Figure 72: Quick release, version V, with axle (1) and clamping lever (2)
Flip the quick release lever into the recess.
Figure 73: Flipping the quick release into the recess (1)
Crash caused by unfastened quick release
The clamping force of the quick release lever is set
once during assembly and is not an indication that the
wheel axle is sufficiently fastened. The axle may come
loose if the closed quick release is turned. This will
result in a crash and injuries.
Never adjust or turn a quick release after closing it,
e.g. to correct the final position.
CAUTION
!
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Turn the axle on the quick release clockwise until
the axle is firmly in place.
Pull the lever from the recess and clamp it properly.
The clamping force of the lever is not an indication
of the tightening torque of the axle.
Setting the clamping force
If the clamping lever cannot be moved into its proper
final position by pushing it with the hand, or if it is too
loose, its clamping force will need to be readjusted.
Figure 74: Setting the clamping force in the middle of the clamping lever (1)
with a hexagon socket spanner (2)
Open the quick release lever.
Connect a 2.5 mm hexagon socket spanner to the
middle of the clamping lever.
Turn the hexagon socket spanner:
turn clockwise to increase the clamping force and
anti-clockwise to reduce the clamping force.
Clamp the clamping lever.
If the clamping lever is not yet in the proper final
position, repeat the steps until the proper final
position has been achieved.
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Maintenance
8.4.3 Adjusting the tyre pressure
8.4.3.1 Dunlop valve
Figure 75: Dunlop valve with union nut (1) and rim nut (2)
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.
The tyre pressure has been adjusted as per the
data [Data sheet, page 1].
If the tyre pressure is too high, unfasten the union
nut, let off 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.
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8.4.3.2 Presta valve
Figure 76: Presta valve with valve insert (1), knurled nut (2) and rim nut (3)
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
data [Data sheet, page 1].
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.
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Maintenance
8.4.3.3 Schrader valve
Figure 77: Schrader valve with rim nut (1)
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
data [Data sheet, page 1].
Remove the bicycle pump.
Screw the valve cap tight.
Screw the rim nut gently against the rim with the
tips of your fingers.
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8.4.4 Adjusting the gear shift
If you cannot select the gears effortlessly, you will
need to adjust the setting for the shift cable tension.
Carefully pull the adjusting sleeve away from the
shifter housing, turning it as you do so.
Check the gear shift function after each adjustment.
8.4.5 Cable-operated gear shift, single-cable
Alternative
For a smooth gear shift, adjust the adjusting
sleeves on the shifter housing.
Figure 78: Adjusting sleeve (1) for the single-cable cable-operated gear shift
with shifter housing (2), example
If you are unable to adjust the gear shift in this way, the
specialist dealer will need to check the gear shift
assembly.
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Maintenance
8.4.6 Cable-operated gear shift, dual-cable
Alternative
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 79: Adjusting sleeves (2) on two alternative versions (A andB) of a
dual-cable cable-operated gear shift on the chain stay (1)
2
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8.4.7 Cable-operated twist grip, dual-cable
Alternative
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 80: Twist grip with adjusting sleeves (1) and play of the gear shift (2)
2
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Maintenance
8.4.8 Offsetting the brake lining wear
8.4.9 Hydraulically operated rim brake
Alternative
The setting bolt on the brake lever of the hydraulic rim
brake is used to offset the brake lining wear. If the
profile of the brake linings has a remaining depth of
just 1 mm, the brake linings need to be replaced.
In order to reduce the free travel and offset the
brake lining wear, screw the setting bolt in.
In order to increase the free travel, screw the setting
bolt out.
With the optimum setting the pressure point, i.e. the
point at which the brake takes effect, is reached
after 10 mm of free travel.
Figure 81: Brake lever (1) of the hydraulically operated rim brake with setting
bolt (2)
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8.4.10 Hydraulically operated disc brake
Alternative
The brake pad wear on the disc brake does not require
readjustment.
8.4.11 Replacing the lighting
Alternatively a 3 watt or 1.5 watt lighting system can be
installed.
Only use components of the respective power class
for replacement.
8.4.12 Setting the headlight
The headlight must be set, so that its light beam
meets the road 10 m in front of the bicycle.
8.4.13 Repair by the specialist dealer
Special knowledge and tools are required for many
repairs. Only a specialist dealer may carry out the
following repairs, for instance:
Replacing tyres and rims,
Replacing brake pads and brake linings,
Replacing and tensioning the chain.
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Maintenance
8.4.14 Replacing the lighting
Alternatively a 3 watt or 1.5 watt lighting system can be
installed.
Only use components of the respective power class
for replacement.
8.4.15 Setting the headlight
The headlight must be set, so that its light beam
meets the road 10 m in front of the bicycle.
8.4.16 Repair by the specialist dealer
Special knowledge and tools are required for many
repairs. Only a specialist dealer may carry out the
following repairs, for instance:
Replacing tyres and rims,
Replacing brake pads and brake linings,
Replacing and tensioning the chain.
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8.4.17 First aid
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. Depending on the type of error, the drive will
also be automatically switched off.
Fire and explosion due to faulty batteries
The safety electronics may fail if the battery is
damaged or defective. 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
!
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Maintenance
8.4.18 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 charge status
indicator LEDs do not light up.
If the LEDs of the charge status 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.
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8.4.18.1 System 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.
8.4.18.2 Special system messages
Make a note of the system message. You will find
the complete system error list in the appendix.
Code Remedy
410, 418 Check whether buttons are jammed because dirt
has got into them, for example. Clean the buttons
if necessary.
430 Charge internal display battery.
502 Check the light and its cabling.
Re-start the system.
Contact your specialist dealer if the problem
persists.
530, 591,
655
Turn off the drive system.
Remove the battery.
Insert the battery again.
Re-start the system.
Contact your specialist dealer if the problem
persists.
Table 31: Error eradication using the code
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Maintenance
If the system message is still displayed, contact
your specialist dealer.
540, 605 The bicycle is outside the permitted temperature
range.
Switch the bicycle off to cool the drive unit down or
warm it up to the permitted temperature range.
Re-start the system.
Contact your specialist dealer if the problem
persists.
550 Remove the electrical load.
Re-start the system.
Contact your specialist dealer if the problem
persists.
592 Insert a compatible display.
Re-start the system.
Contact your specialist dealer if the problem
persists.
602 Disconnect the charger from the battery.
Re-start the system.
Plug the charger into the battery.
Contact your specialist dealer if the problem
persists.
605 Disconnect the charger from the battery.
Leave the battery to cool.
Contact your specialist dealer if the problem
persists.
620 Replace the charger.
Contact your specialist dealer if the problem
persists.
656 Contact your specialist dealer to install a software
update.
7xx Please observe the manufacturer's operating
instructions.
No
screen
display
Re-start your drive system by switching it on and
off.
Code Remedy
Table 31: Error eradication using the code
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Model Passion E7R
Type no. 19-17-3076
Motor Active Plus
Display Intuvia
Charger (included in supply) Down tube/Seat tube
Brakes 2
Rear derailleur Magura HSI-22
Rear derailleur Shimano Nexus
Gears 7
Fork Rigid fork
Tyre Big Ben 50-622, black/coffee, reflex, K-Guard
Rims DBM-2
Mudguard Curana with integrated light
Saddle Velo VL-8090 (retro style)
Headset Velo "Leather" (TBD)
Handles STANDWELL, SW-RA031J
Pedals C-157
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Maintenance
8.5 Accessories
For bicycles without a kickstand we recommend a
parking stand into which either the front or rear wheel
can be inserted securely. 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.
8.5.1 Child seat
Description Article number
Protective cover for electrical
components 080-41000 ff
Panniers, system component* 080-40946
Rear wheel basket, system
component* 051-20603
Bicycle box, system component* 080-40947
Parking stand universal stand XX-TWO14B
Lighting set, system component** 070-50500 ff
Table 32: Accessories
Crash caused by incorrect child seat
Neither the pannier rack nor the bicycle 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.
WARNING
!
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Crash caused by improper handling
When using child seats, the riding properties and the
stability of the bicycle change considerably. This can
cause a loss of control, a crash and injuries.
You should practice how to use the child seat safely
and reliably before using the bicycle in public
spaces.
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.
Observe the legal regulations on the use of child
seats.
Observe the operating and safety notes for the child
seat system.
Never exceed the total weight of the bicycle.
CAUTION
!
CAUTION
!
NOTICE
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Maintenance
8.5.2 Bicycle trailer
A bicycle which is approved for towing a trailer is
equipped with the relevant information sign. Only
bicycle trailers with a support load and total mass
which do not exceed the permitted values must be
used.
The specialist dealer will advise on choosing a suitable
child seat system for the child and the bicycle.
The specialist dealer must mount 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 bicycle 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
bicycle's permitted total weight is not exceeded.
The specialist dealer will provide instruction on how to
handle the bicycle and the child seat.
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.
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
!
NOTICE
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Figure 82: Trailer sign
8.5.3 Pannier rack
The specialist dealer will advise on choosing a suitable
trailer system for the bicycle. The specialist dealer
must install the trailer the first time to ensure that it is
safely fitted.
The specialist dealer will advise on choosing a suitable
pannier rack.
The specialist dealer must mount the pannier rack the
first time to ensure that it is safely fitted.
When installing a pannier rack, the specialist dealer
makes sure that the fastening mechanism for the rack
is suitable for the bicycle 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 bicycle is not exceeded.
The specialist dealer will provide instruction on how to
handle the bicycle and the pannier rack.
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Recycling and disposal
9 Recycling and disposal
Risk of fire and explosion
The safety electronics on damaged or faulty batteries
may fail. The residual voltage can cause a short
circuit. Batteries may self-ignite and explode.
Remove batteries with external damage from
service immediately and never charge them.
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 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.
Chemical burns to the skin and eyes
Liquids and vapours may leak from damaged or faulty
batteries. 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
!
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182
This device is marked according to the European
Directive 2012/19/EU on waste electrical and
electronic equipment – WEEE and accumulators
(Directive 2006/66/EC). The directive provides the
framework for the EU-wide return and recycling of
used devices, which are collected separately and in
an environmentally sound manner.
The bicycle, battery, motor, display and charger are
recyclable materials. You must dispose of and recycle
them separately from domestic waste in compliance
with the 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 bicycle, battery or charger for
disposal.
The bicycle, display, 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
bicycle in a dry place, free from frost, where they
are protected from direct sunlight.
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Appendix
9.1 EC declaration of conformity
Translation of the original EC declaration of conformity
The manufacturer:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Straße 2
50739 Köln, Germany
hereby declares that the electrically power assisted cycles of types:
19-17-1007, 19-17-1008, 19-17-1052, 19-18-1020, 19-18-1021, 19-18-1022, 19-18-1023, 19-18-1027,
19-18-1053, 19-18-1059, 19-18-1060, 19-18-1060, 19-18-1061, 19-18-1062, 19-18-4013, 19-18-4013,
19-18-4014, 19-18-4015
year of manufacture 2018 and year of manufacture 2019,
comply with all applicable requirements of Machinery Directive 2006/42/EC.
The following standards were used: EN ISO 12100:2010 Safety of machinery General principles
of design Risk assessment and reduction, EN 15194:2015, Cycles Electrically power assisted
cycles – EPAC bicycles, EN ISO 4210, Cycles – Safety requirements for bicycles,
EN 11243:2016, Cycles – Luggage carriers for bicycles – Requirements and test methods and
EN 82079 1:2012, Preparation of instructions for use – Structuring, content and presentation –
Part 1: General principles and detailed requirements.
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, 22/11/2018
……………………………………………………………………………………………………
Place, date and signature
Egbert Hageböck
-Chairman-
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9.2 Parts list
Model Sturmvogel Evo 1 29
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Fork Suntour XCM-32 LO CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 57-622 Perf. Folding
Rims SHEANG LIH, AS-T30-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 33: Parts list for Sturmvogel Evo 1 29
Model Sturmvogel Evo 2 29
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Fork Suntour XCR-34 LOR Air CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 57-622 SnakeSkin TLE
Rims SHEANG LIH, AS-T30-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 34: Parts list for Sturmvogel Evo 2 29
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Appendix
Model Sturmvogel Evo
Motor Brose T
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Shimano BR-MT201
Rear derailleur Shimano Alfine
Gear shift 8
Fork Rigid fork
Seat post Kalloy, SP-719
Tyres and size Fat Frank, 60-559 K-Guard
Rims Strongman, BF-1
Saddle VELO VL-1221 (brown)
Stem Kalloy, AS-ML2
Headset ChinHaur
Handles VELO, VLG-649D2S (brown)
Pedals C122B
Table 35: Parts list for Sturmvogel Evo
Model Sturmvogel Evo Street
Type number 19-17-1008
Motor Brose T
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Shimano BR-MT201
Rear derailleur Shimano Alfine
Gear shift 8
Fork Rigid fork
Seat post Kalloy, SP-719
Tyres and size Fat Frank, 60-559 K-Guard
Rims Strongman, BF-1
Mudguard Sunnywheel alloy 65 mm
Saddle VELO VL-1221 (brown)
Stem Kalloy, AS-007N
Headset ChinHaur
Handles VELO, VLG-649D2S (brown)
Pedals C122B
Table 36: Parts list for Sturmvogel Evo Street
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Model Sturmvogel Evo Street
Type number 19-17-1052
Motor Brose T
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Shimano BR-MT201
Rear derailleur Shimano Alfine
Gear shift 8
Fork Rigid fork
Seat post Kalloy, SP-719
Tyres and size Fat Frank, 60-559 K-Guard
Rims Strongman, BF-1
Mudguard Sunnywheel alloy 65 mm
Saddle VELO VL-1221 (brown)
Stem Kalloy, AS-007N
Headset ChinHaur
Handles VELO, VLG-649D2S (brown)
Pedals C122B
Table 37: Parts list for Sturmvogel Evo Street
Model E-Stream Evo 1 27.5+
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Fork Suntour XCM-32 LO CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 70-584 Perf. Folding
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 38: Parts list E-Stream Evo 1 27.5+
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Appendix
Model E-Stream Evo 1 29
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Gear shift 9
Fork Suntour XCM-32 LO CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 57-622 Perf. Folding
Rims SHEANG LIH, AS-T30-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 39: Parts list E-Stream Evo 1 29
Model E-Stream Evo 1 TR2
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour XCR-34 LOR Air CTS Boost
Damper Suntour Unair LOR8
Seat post Kalloy, SP-368
Tyres and size Smart Sam, 70-584 K-Guard
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1812 D2
Pedals VP, Bulls 171206
Table 40: Parts list E-Stream Evo TR2
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Model E-Stream Evo TR3
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5/4
Rear derailleur Shimano Deore
Gear shift 10
Fork Fox Rhythm 34 Float Boost
Damper DPS Performance
Seat post Kalloy, SP-368
Tyres and size Smart Sam, 70-584 Perf. Folding
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1812 D2
Pedals VP, Bulls 171206
Table 41: Parts list E-Stream Evo TR3
Model E-Stream Evo 2 27.5+
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5/4
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour Aion-35 LOR Air CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 70-584 SnakeSkin TLE
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 42: Parts list E-Stream Evo 2 27.5
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Appendix
Model E-Stream Evo TR3
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5/4
Rear derailleur Shimano Deore
Gear shift 10
Fork Fox Rhythm 34 Float Boost
Damper DPS Performance
Seat post Kalloy, SP-368
Tyres and size Smart Sam, 70-584 Perf. Folding
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1812 D2
Pedals VP, Bulls 171206
Table 43: Parts list E-Stream Evo TR3
Model E-Stream Evo 3 29
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5/4
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour Aion-35 LOR Air CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 57-622 SnakeSkin TLE
Rims SHEANG LIH, AS-T30-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 44: Parts list E-Stream Evo 3 29
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Model E-Stream Evo AM3
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5/4
Rear derailleur Shimano Deore
Fork Fox Rhythm 36 Float Boost
Damper DPS Performance
Telescopic seat post Kind Shock Lev Si
Tyres and size Nobby Nic, 70-584 SnakeSkin TLE
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, SETA M1
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1812 D2
Pedals VP, Bulls 171206
Table 45: Parts list E-Stream Evo AM3
Model E-Stream Evo AM4
Motor Brose SL
Display BLOKS 14d
Rechargeable battery SuperCore
Battery location Integrated
Brakes Magura MT5
Rear derailleur Shimano XT
Gear shift 11
Fork Fox Rhythm 36 Float Boost
Damper DPS Performance
Telescopic seat post Kind Shock Lev Si
Tyres and size Magic Mary/Nobby Nic, 70-584 SnakeSkin TLE
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, SETA M1
Stem Kalloy, AS-ML1
Headset FSA, Orbit
Handles ERGON, GE10
Pedals VP, Bulls 171206
Table 46: Parts list E-Stream Evo AM4
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Appendix
Model E-Stream Evo 2 27.5+
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M275
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour XCR-34 LOR Air CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 70-584 SnakeSkin TLE
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 47: Parts list E-Stream Evo 2 27.5+
Model E-Stream Eva 2 27.5+
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M276
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour XCR-34 LOR Air CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 70-584 SnakeSkin TLE
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 48: Parts list E-Stream Eva 2 27.5+
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Model E-Stream Eva 127.7+
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M276
Rear derailleur Shimano Deore
Gear shift 9
Fork Suntour XCM-32 LO CTS Boost
Seat post Kalloy, SP-368
Tyres and size Rocket Ron, 70-584 Perf. Folding
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1682AD3
Pedals VP, Bulls 171206
Table 49: Parts list E-Stream Eva 1 27.7+
Model E-Stream Eva TR2
Motor Brose S
Display BLOKS 14d
Rechargeable battery EVO 650
Battery location Integrated
Brakes Tektro HD-M276
Rear derailleur Shimano Deore
Gear shift 10
Fork Suntour XCR-34 LOR Air CTS Boost
Damper Suntour Unair LOR8
Seat post Kalloy, SP-368
Tyres and size Smart Sam, 70-584 Perf. Folding
Rims SHEANG LIH, AS-T35-N
Saddle JUSTEK, 2059DRN
Stem Kalloy, AS-ML1
Headset ChinHaur
Handles VELO, VLG-1812 D2
Pedals VP, Bulls 171206
Table 50: Parts list E-Stream Eva TR2
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 192 Tuesday, December 4, 2018 3:50 PM
034-03217_1.0_04.12.2018 193
Table of figures
9.3 Table of figures
Figure 1: Type plate, example, 18
Figure 2: Bicycle from right; E-Stream EVA 2 27.5+, 27 used as
example, 26
Figure 3: Components of the wheel – example showing front
wheel, 27
Figure 4: Bicycle without suspension (1) and with suspension (2)
when riding over an obstacle, 29
Figure 5: Example showing Suntour fork: The stem and handlebars
are fastened to the fork shaft (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), 30
Figure 6: Example showing a Yari fork diagram with the operating
elements: 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), 31
Figure 7: Example showing FOX rear frame damper, 32
Figure 8: Example showing Suntour rear frame damper, 33
Figure 9: Bicycle brake system with a disc brake, example, 34
Figure 10: Diagram of drive system, 35
Figure 11: Diagram of electric drive system, 36
Figure 12: Evo 650 battery details, 38
Figure 13: Display details, 40
Figure 14: On-screen indicators overview, 41
Figure15: Fastening the transport securing device, 49
Figure 16: Fully inserting the axle, 57
Figure 17: Tightening the axle, 57
Figure 18: Pushing the quick release lever into the axle, 58
Figure 19: Tightening the securing screw, 58
Figure 20: Tightening the inserted axle, 59
Figure 21: Tightening the axle, 59
Figure 22: Pushing the axle into the hub, 61
Figure 23: Tightening the axle, 61
Figure 24: Pushing the quick release lever into the axle, 62
Figure 25: Securing the lever, 62
Figure 26: Perfect position for the clamping lever, 63
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 193 Tuesday, December 4, 2018 3:50 PM
Table of figures
034-03217_1.0_04.12.2018
194
Figure 27: Adjusting the quick release clamping force, 63
Figure 28: Open and closed flange, 65
Figure 29: Pushing the quick release in, 65
Figure 30: Adjusting the clamping, 66
Figure 31: Closing the quick release, 66
Figure 32: Pushing the quick release in, 67
Figure 33: Spacing between lever and fork leg, 68
Figure 34: 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, 68
Figure 35: Pushing the Kabolt axle in, 70
Figure 36: Horizontal saddle tilt, 74
Figure 37: Optimal saddle height, 75
Figure 38: Seat post quick release (3) with clamping lever (5) and
setting bolt (4) in the open position (1) and in the direction
of the closed position (2), 75
Figure 39: Detailed view of the seat post examples of the minimum
insertion depth marking, 76
Figure 40: The seat post activation lever can be mounted either on
the left (1) or the right (2) side of the handlebars, 77
Figure 41: Knee cap perpendicular line, 78
Figure 42: Open (2) and closed (1) clamping lever on the stem;
by.schulz speedlifter used as an example, 80
Figure 43: Pulling locking lever upwards; by.schulz speedlifter used
as an example, 82
Figure 44: Using the twist knob (1) to adjust the pressure point, 83
Figure 45: Brake lever grip distance, 84
Figure 46: Using the setting screw (2) to adjust the distance from the
brake lever to the handlebar grip (1), 85
Figure 47: Screw caps in different designs, 87
Figure 48: Negative deflection setting wheel on the suspension fork
crown, 89
Figure 49: Suntour rebound adjuster (2) on the fork (1), 90
Figure 50: Suntour compression adjuster with the OPEN (1) and
LOCK (2) positions, 91
Figure 51: FOX rebound adjuster (1) on the fork, 95
Figure 52: FOX compression adjuster with the OPEN (1) and
HARD (2) positions, 96
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 194 Tuesday, December 4, 2018 3:50 PM
034-03217_1.0_04.12.2018 195
Table of figures
Figure 53: 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), 98
Figure 54: FOX compression adjuster on the rear frame damper with
the OPEN (1), MEDIUM (2) and HARD (3) positions, 99
Figure 55: Fine adjustment of the OPEN position is made using the
adjuster (4), 99
Figure 56: FOX rebound adjuster (1) on the rear frame damper, 100
Figure 57: Attaching the display, 118
Figure 58: Removing the display, 119
Figure 59: Display with high (2) and low (1) gear
recommendation, 126
Figure 60: Down shifter (1) and up shifter (2) on the left (I) and
right (II) shift, 127
Figure 61: 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), 129
Figure 62: Front (2) and rear (1) brake lever; Shimano brake used as
an example, 134
Figure 63: Suntour compression adjuster with the OPEN (1) and
LOCK (2) positions, 135
Figure 64: FOX compression adjuster with the OPEN (1) and
HARD (2) positions, 136
Figure 65: FOX compression adjuster on the rear frame damper with
the OPEN (1), MEDIUM (2) and HARD (3) positions, 137
Figure 66: Fine adjustment of the OPEN position is made using the
adjuster (4), 137
Figure 67: Checking the chain and belt tension, 152
Figure 68: Wheel quick release, version I, with clamping lever (2),
fork (1) and setting nut (3), 157
Figure 69: Quick release, version II, with clamping lever (1), axle (2),
setting nut (3), and detailed view of the open (4) and
closed (5) flange, 158
Figure 70: Quick release, version III, with axle (1) and clamping
lever (2), 159
Figure 71: Wheel quick release, version IV, with twist knob (1) and
clamping lever (2), 160
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 195 Tuesday, December 4, 2018 3:50 PM
Table of figures
034-03217_1.0_04.12.2018
196
Figure 72: Quick release, version V, with axle (1) and clamping
lever (2), 161
Figure 73: Flipping the quick release into the recess (1), 161
Figure 74: Setting the clamping force in the middle of the clamping
lever (1) with a hexagon socket spanner (2), 162
Figure 75: Dunlop valve with union nut (1) and rim nut (2), 163
Figure 76: Presta valve with valve insert (1), knurled nut (2) and rim
nut (3), 164
Figure 77: Schrader valve with rim nut (1), 165
Figure 78: Adjusting sleeve (1) for the single-cable cable-operated
gear shift with shifter housing (2), example, 166
Figure 79: Adjusting sleeves (2) on two alternative versions
(A and B) of a dual-cable cable-operated gear shift on the
chain stay (1), 167
Figure 80: Twist grip with adjusting sleeves (1) and play of the gear
shift(2),168
Figure 81: Brake lever (1) of the hydraulically operated rim brake
with setting bolt (2), 169
Figure 82: Trailer sign, 180
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 196 Tuesday, December 4, 2018 3:50 PM
034-03217_1.0_04.12.2018 197
List of tables
9.4 List of tables
Table 1: Meanings of the signal words, 13
Table 2: Safety markings on the product, 14
Table 3: Area of use, 15
Table 4: Bicycle type, 15
Table 5: Information on the type plate, 16
Table 6: Identification number of the operating instructions, 19
Table 7: Bicycle definition by type number, model and bicycle
type, 19
Table 8: Rechargeable battery technical data, 37
Table 9: Operating element technical data, 39
Table 10: Display overview, 40
Table 11: On-screen indicator overview, 41
Table 12: Levels of assistance display l, 42
Table 13: Journey information, 42
Table 14: Battery charge status indicator, 43
Table 15: Bicycle technical data, 44
Table 16: Rechargeable battery technical data, 44
Table 17: Rechargeable battery technical data, 45
Table 18: Operating element technical data, 45
Table 19: Emissions from the bicycle*, 46
Table 20: USB port technical data, 46
Table 21: Tightening torque values, 46
Table 22: Storage temperature for batteries, the bicycle and
charger, 50
Table 23: Working environment temperature, 52
Table 24: Handlebars clamping screw maximum tightening
torque, 79
Table 25: Overview of Suntour forks, 86
Table 26: Filling pressure pump of the Suntour air forks, 88
Table 27: Filling pressure table of the FOX air fork, 93
Table 28: Filling pressure table of the FOX air fork, 101
Table 29: Changeable system settings, 122
Table 30: Journey information, 124
Table 31: Error eradication using the code, 174
Table 32: Accessories, 177
Table 33: Parts list for Sturmvogel Evo 1 29, 184
Table 34: Parts list for Sturmvogel Evo 2 29, 184
Table 35: Parts list for Sturmvogel Evo, 185
Table 36: Parts list for Sturmvogel Evo Street, 185
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 197 Tuesday, December 4, 2018 3:50 PM
List of tables
034-03217_1.0_04.12.2018
198
Table 38: Parts list E-Stream Evo 1 27.5+, 186
Table 37: Parts list for Sturmvogel Evo Street, 186
Table 40: Parts list E-Stream Evo TR2, 187
Table 39: Parts list E-Stream Evo 1 29, 187
Table 42: Parts list E-Stream Evo 2 27.5, 188
Table 41: Parts list E-Stream Evo TR3, 188
Table 44: Parts list E-Stream Evo 3 29, 189
Table 43: Parts list E-Stream Evo TR3, 189
Table 46: Parts list E-Stream Evo AM4, 190
Table 45: Parts list E-Stream Evo AM3, 190
Table 48: Parts list E-Stream Eva 2 27.5+, 191
Table 47: Parts list E-Stream Evo 2 27.5+, 191
Table 50: Parts list E-Stream Eva TR2, 192
Table 49: Parts list E-Stream Eva 1 27.7+, 192
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 198 Tuesday, December 4, 2018 3:50 PM
034-03217_1.0_04.12.2018 199
Index
9.5 Index
A
Air chamber, 32
Air valve
Fork, 31
Rear frame damper, 32
Alternative equipment, 17
Alternative version, 17
B
Back-pedal brake,
-braking, 134
Battery, 37, 38
- charging, 112
- checking, 56
- disposing of, 182
- waking, 113
Belt tension, 151
Bike stand, see Kickstand
Brake calliper, 34
Brake disc, 34
Brake lever,
- adjusting the pressure
point 83
Brake lining, 34
- maintaining, 150
Brake,
- using the transport
securing system, 49
Break in operation, 51
- carrying out, 51
- preparing, 51
C
Chain drive, 35
Chain guard,
- checking, 105
Chain tension, 151
Chain wheel, 35
Chain, 26, 35
- maintaining, 151
- replacing, 170, 171
Charge status indicator, 38
Charger,
- disposing of, 182
Clamping force,
- Checking the quick
releases, 61, 158
- Setting the quick
releases, 61, 158
D
Data sheet, 1
Direction of travel, 35
Display, 39
- attaching, 118
- removing, 118
Drive system, 36
- switching off, 115
- switching on, 114, 116
Driving light, 39
- checking function, 105
- replacing, 170, 171
E
EC declaration of conformity,
183
F
Fork lock,
Position, 31
Fork, 27
Fork end, 27
structure, 30
Frame number, 1
Frame, 26
Front wheel brake, 34
- braking, 134
Front wheel, see Wheel
G
Gear shift twist grip,
- checking, 150
Gear shift,
- maintaining, 150
- switching, 126
H
Handlebars, 26
Headlight, 36
Hub, 27
I
Initial commissioning 54
J
Journey information, 42, 124
- resetting, 122
- switching, 121, 125
L
Level of assistance, 42, 43
- selecting, 121, 124
Lever, 32
Lighting, see Driving light
M
Mass, see Weight
Minimum insertion depth
marking, 76
Model year, 18
Model, 1
Motor, 36
Mudguards,
- checking, 105
O
On-screen indicator, 126, 180
Operating status indicator, 38
O-ring, 32
P
Packaging, 53
Pannier rack,
- changing, 108
- checking, 105
- using, 107
Parts list, 183
Pedal, 35
Push assist,
- using, 120, 123
Q
Quick release,
Position, 31
R
Rear frame damper,
structure, 32, 33
Rear light, 36
Rear wheel brake, 34
Rebound damper adjuster,
Position, 31
Rim, 27
- checking, 149
- replacing, 170, 171
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 199 Tuesday, December 4, 2018 3:50 PM
Index
034-03217_1.0_04.12.2018
200
Roller brake,
-braking, 134
S
Saddle, 26
- changing the saddle tilt,
73
- changing the seat length,
78
- determining the saddle
height, 74, 78
Seat post, 26
- clamping, 82, 84, 89, 94
Setting wheel, 32
Shifter,
- checking, 150
- setting, 153, 165, 166,
169
Spoke, 27
Storage, 49
Storing, see Storage
Suspension fork head, 27
Suspension fork, 28, 29
System setting,
changeable, 122
T
Transportation, 47
Transporting, see
Transportation
Type number, 1, 18
Tyre pressure, 1
Tyre size, 1
Tyres, 27
- checking, 149
- replacing, 170, 171
U
USB port,
- using, 121
V
Valve cap, 31
Valve, 27
Dunlop valve, 27
Presta valve, 27
Schrader valve, 27
W
Weight,
permitted total weight, 18
Unladen weight, 1
Wheel circumference, 1
Wheel,
- maintaining, 149
Winter break, see break in
operation
Working environment, 52
EN_034-03217_1.0_BULLS Brose Bloks MY19_Inhalt.book Page 200 Tuesday, December 4, 2018 3:50 PM
Text and images:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Straße 2
50739 Köln, Germany
Translation:
Tanner Translations GmbH+Co
Markenstraße 7
40227 Düsseldorf, Germany
Operating instructions: 034-03217_1.0_04.12.2018
EN_034-03217_1.0_BULLS Brose Bloks MY19_COVER.book Page 148 Tuesday, December 4, 2018 3:28 PM
WWW.BULLS.DE
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Straße 2
50739 Köln, Germany
Tel.: +49 221 17959 0
YOUR BULLS SPECIALIST DEALER
EN_034-03217_1.0_BULLS Brose Bloks MY19_COVER.book Page 149 Tuesday, December 4, 2018 3:28 PM
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