772980

Kettler 2020 Handleiding

64
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IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
MY20P02-1 - 1_1.0_13.01.2020
Operating instructions
Bicycle
MY20K08-2_1.0_13.01.2020 1
Contents
Contents
1 About these operating instructions 3
1.1 Manufacturer 3
1.2 Identifying the operating instructions 3
1.3 Laws, standards and directives 3
1.4 For your information 4
1.4.1 Warnings 4
1.4.2 Markups 4
2 Safety 5
2.1 General warnings 5
2.1.1 Toxic substances 5
2.1.1.1 Brake fluid 5
2.2 Requirements for the rider 6
2.3 Vulnerable groups 6
2.4 Personal protective equipment 6
2.5 Safety markings and safety instructions 6
2.6 Emergency 6
2.6.1 What to do in an emergency 6
2.6.2 Leaking fluids 6
2.6.2.1 Brake fluid 6
2.6.2.2 Oils and lubricants from the fork 6
2.6.2.3 Oils and lubricants from the rear frame
damper 6
3Overview 7
3.1 Description 8
3.1.1 Wheel 8
3.1.1.1 Valve 8
3.1.2 Suspension 8
3.1.2.1 Rigid fork 8
3.1.2.2 Suspension fork 8
3.1.2.3 Steel suspension fork 9
3.1.2.4 Air suspension fork 10
3.1.3 Brake system 10
3.1.3.1 Rim brake 11
3.1.3.2 Disc brake 11
3.1.3.3 Back-pedal brake 12
3.2 Proper use 13
3.3 Improper use 14
3.4 Technical data 15
3.4.1 Bicycle 15
3.4.2 Tightening torque 15
3.5 Environmental requirements 16
3.6 Description of controls and screens 18
3.6.1 Handlebars 18
4 Transporting and storing 19
4.1 Physical transport characteristics 19
4.1.1 Dimensions during transportation 19
4.1.2 Transport weight 19
4.1.3 Designated handles/lifting points 19
4.2 Transporting 19
4.3 Storing 19
5 Assembly 20
5.1 Required tools 20
5.2 Unpacking 20
5.2.1 Scope of delivery 20
5.3 Commissioning 20
5.3.1 Installing the wheel in the Suntour fork 21
5.3.1.1 Screw-on axle (15 mm) 21
5.3.1.2 Screw-on axle (20 mm) 22
5.3.1.3 Quick release axle 22
5.3.1.4 Quick release 26
5.3.2 Installing the wheel in the FOX fork 27
5.3.2.1 Quick release (15 mm) 27
5.3.2.2 Kabolt axle 29
5.3.3 Checking the stem and handlebars 29
5.3.3.1 Checking connections 29
5.3.3.2 Firm hold 30
5.3.3.3 Checking the headset backlash 30
5.4 Selling bicycles 30
6 Operation 31
6.1 Risks and hazards 31
6.1.1 Personal protective equipment 31
6.2 Instruction and customer service 32
6.3 Adjusting the bicycle 32
6.3.1 Adjusting the saddle 32
6.3.1.1 Adjusting the saddle tilt 32
6.3.1.2 Determining the seat height 32
6.3.1.3 Adjusting the seat height with quick
release 34
6.3.1.4 Height-adjustable seat post 34
6.3.1.5 Adjusting the seat position 36
6.3.2 Adjusting the handlebars 37
6.3.3 Adjusting the stem 37
6.3.3.1 Adjusting the height of the handlebars 37
6.3.3.2 Adjusting the quick release clamping
force 37
6.3.4 Setting the brake 38
6.3.4.1 Setting the grip distance on a
Magura HS33 brake lever 39
6.3.4.2 Setting the grip distance on a
Magura HS22 brake lever 40
6.3.4.3 Setting the grip distance on a
Magura disc brake lever 40
6.3.4.4 Setting the pressure point on a
Magura brake lever 42
6.3.5 Retracting the brake linings 42
6.3.6 Adjusting the Suntour fork 42
6.3.6.1 Adjusting the negative deflection 43
6.3.6.2 Adjusting the steel suspension fork
negative deflection 43
MY20K08-2_1.0_13.01.2020 2
Contents
6.3.6.3 Adjusting the air suspension fork
negative deflection 43
6.3.6.4 Adjusting the air suspension fork
rebound 44
6.3.7 Adjusting the FOX fork 44
6.3.7.1 Adjusting the negative deflection 45
6.3.7.2 Adjusting the rebound 46
6.4 Accessories 47
6.4.1 Child seat 47
6.4.2 Bicycle trailer 48
6.4.3 Pannier rack 48
6.5 Before each ride 49
6.6 Check list before each ride 49
6.7 Using the kickstand 50
6.7.1 Raising the kickstand 50
6.7.1.1 Parking the bicycle 50
6.8 Using the pannier rack 50
6.9 Brake 52
6.9.1 Using the brake lever 53
6.9.2 Using the back-pedal brake 53
6.10 Suspension and damping 53
6.11 Gear shift 55
7 Cleaning and servicing 58
7.1 Cleaning after each ride 58
7.1.1 Cleaning the suspension fork 58
7.1.2 Cleaning the rear frame damper 58
7.1.3 Cleaning the pedals 58
7.2 Basic cleaning 59
7.2.1 Cleaning the frame 59
7.2.2 Cleaning the stem 59
7.2.3 Cleaning the wheel 59
7.2.4 Cleaning the drive elements 59
7.2.5 Cleaning the rear frame damper 59
7.2.6 Cleaning the chain 60
7.2.7 Cleaning the brake 60
7.3 Servicing 60
7.3.1 Servicing the frame 60
7.3.2 Servicing the stem 61
7.3.3 Servicing the fork 61
7.3.4 Servicing the drive elements 61
7.3.5 Servicing the pedals 61
7.3.6 Servicing the chain 61
7.3.7 Servicing the drive elements 61
7.4 Maintenance 61
7.4.1 Wheel 61
7.4.1.1 Checking the tyres 62
7.4.1.2 Checking the rims 62
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 62
7.4.1.4 Checking and adjusting the tyre
pressure – presta valve 62
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 62
7.4.2 Brake system 63
7.4.3 Checking the brake linings for wear 63
7.4.4 Checking the pressure point 63
7.4.5 Checking the brake discs for wear 63
7.4.6 Electrical cables and brake cables 63
7.4.7 Gear shift 63
7.4.8 Stem 63
7.4.9 Checking the belt and chain tension 64
8 Maintenance 66
8.1 Axle with quick release 67
8.1.1 Checking the quick release 67
8.2 Adjusting the gear shift 68
8.2.1 Cable-operated gear shift,
single-cable 68
8.2.2 Cable-operated gear shift,
dual-cable 68
8.2.3 Cable-operated twist grip,
dual-cable 69
9 Troubleshooting, fault clearance
and repair 70
9.1 Repair 70
9.1.1 Original parts and lubricants 70
9.1.2 Replacing the lighting 70
9.1.3 Adjusting the headlight 70
9.1.4 Tyre clearance check 70
10 Recycling and disposal 71
10.1 Assembly report 72
10.2 Maintenance instructions 74
11 Glossary 76
12 Keyword index 79
MY20K08-2_1.0_13.01.2020 3
About these operating instructions
1 About these operating instructions
Thank you for your trust!
KETTLER bicycles are premium quality vehicles.
You have made an excellent choice. Your
specialist dealer will provide you with guidance
and instruction and assemble your product. Your
specialist dealer will also be happy to assist you in
the future whether you require maintenance,
conversion or repair.
You are receiving these operating instructions
with your new bicycle. Please take time to become
familiar with your new bicycle and follow the tips
and suggestions in the operating instructions.
They will help you to enjoy your bicycle for a long
time to come. We hope you have fun and wish you
well on all of your rides!
These operating instructions are mainly designed
for the rider or the operator. They aim to ensure
that non-professionals can use the bicycle safely.
Download the operating instructions onto your
phone at the following link,
so that you can use them
when you are out riding:
https://www.kettler-alu-
rad.de/gb/en/index/
service.html.
1.1 Manufacturer
The manufacturer of the bicycles is:
KETTLER Alu-Rad GmbH
Longericher Straße 2
50739 Köln, Germany
Tel.: +49 6805 6008-0
Fax: +49 6805 6008-3098
E-Mail: info@kettler-alu-rad.de
Website: www.kettler-alu-rad.de/gb/en/
index.html
1.2 Identifying the operating
instructions
You will find identification number at the bottom
left-hand side of each page. The identification
number is composed of the document number, the
version number and the release date.
1.3 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
• ISO 4210-1: 2015-01 – Cycles – Safety
requirements for bicycles
• EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
• IEC/IEEE 82079-1:2019-05 – International
Standard for Preparation of information for use
(instructions for use) of products
• ISO 17100:2016-05 Translation Services –
Requirements for translation services.
Notice
These operating instructions are not a substitute
for personal instruction by the supplying specialist
dealer.
These operating instructions form an integral part
of the bicycles. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Sections are also designed especially for the
specialist dealer. These sections aim to ensure
that specialist dealers complete initial assembly
and maintenance safely and reliably. The
sections for specialist dealers are highlighted in
grey and marked with a spanner symbol.
Identification number MY20K08-2_1.0_13.01.2020
MY20K08-2_1.0_13.01.2020 4
About these operating instructions
1.4 For your information
Different markings are used in the operating
instructions to make them easier to read.
1.4.1 Warnings
Warnings indicate hazardous situations and
actions. You will find warnings in the operating
instructions:
1.4.2 Markups
You will find stylised forms of typeface in the
operating instructions:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries if ignored.
Low-risk hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!
Stylised form Use
Italics Glossary term
Underlined in blue Link
Underlined in grey Cross references
Check marks Requirements
Triangle Instruction for action
1Instruction for
action
Several instructions for
action in specified order
Result of the action
SPACED Indicators on the display
screen
• Bulleted lists
Only applies to bicycles
with this equipment
Each type has a different
kind of equipment. A
note beneath the
heading indicates
components which can
be used as an
alternative.
Table 1: Markups
Instructions for specialist dealers are highlighted
in grey. They are indicated by a screwdriver
symbol. Information for specialist dealers does
not require non-professionals to take any action.
MY20K08-2_1.0_13.01.2020 5
About these operating instructions
2 Safety
2.1 General warnings
2.1.1 Toxic substances
2.1.1.1 Brake fluid
Death due to intoxication
Brake fluid may leak out after an
accident or due to material fatigue.
Brake fluid can be fatal if
swallowed or inhaled.
First aid treatment
Remove those affected from the
danger area to fresh air.
Never leave those affected
unattended.
Immediately remove any
clothing items contaminated
with brake fluid.
Never inhale vapours or
aerosols. Ensure sufficient
ventilation.
Wear gloves and safety gloves
as protective equipment.
Keep unprotected persons
away.
Take care with leaked brake
fluid as it poses a slip hazard.
Keep leaked brake fluid away
from naked flames, hot surfaces
and sources of ignition.
Avoid contact with skin and
eyes.
DANGER
!
After inhalation
Take in fresh air. Immediately
consult a doctor in case of any
discomfort.
After skin contact
Wash affected skin with soap
and water and rinse well.
Remove contaminated clothing.
Consult doctor in the event of
pain or discomfort.
After contact with eyes
Rinse eyes under flowing water
for at least ten minutes with the
lids open; also rinse under lids.
Immediately consult a doctor in
case of any pain or discomfort.
After swallowing
Rinse out mouth with water.
Never induce vomiting. Risk of
aspiration!
If a person is lying on their back
and is vomiting, place them in
the recovery position. Seek
medical advice immediately.
Environmental protection
measures
Never allow brake fluid to flow
into the sewage system, water
courses or groundwater.
Notify the relevant authorities if
fluid penetrates the ground,
water courses or the sewage
system.
MY20K08-2_1.0_13.01.2020 6
About these operating instructions
2.2 Requirements for the rider
The rider must demonstrate adequate physical,
motor and mental abilities to ride on public roads.
2.3 Vulnerable groups
If minors use the bicycle, a legal guardian must
should provide them with comprehensive
instructions.
2.4 Personal protective equipment
Wear a suitable cycling helmet, sturdy footwear
and typical close-fitting clothing for bicycles.
2.5 Safety markings and safety
instructions
The nameplate contains these safety markings
and safety instructions:
2.6 Emergency
2.6.1 What to do in an emergency
Apply the bicycle brakes until the bicycle
comes to a halt if you should face any danger
on the road. The brake acts as an emergency
stop system in such cases.
2.6.2 Leaking fluids
2.6.2.1 Brake fluid
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
2.6.2.2 Oils and lubricants from the fork
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
compliance with statutory regulations. Contact
your specialist dealer.
2.6.2.3 Oils and lubricants from the rear frame
damper
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
Hazard for the environment due to leaking
brake fluid
Brake system brake fluid is toxic and harmful to the
environment. Brake fluid will contaminate if it enter
the sewers or groundwater.
Repair the brake system immediately if brake
fluid leaks out. Contact your specialist dealer.
Dispose of leaked brake fluid in an
environmentally responsible way as per
statutory regulations. Contact your specialist
dealer.
Symbol Explanation
General warning
Adhere to the instructions for use
Table 2: Meaning of safety markings
CAUTION
!
MY20K08-2_1.0_13.01.2020 7
Overview
3Overview
Figure 1: Bicycle viewed from the right – example
1 Front wheel
2 Front guard
3Fork
4 Headlight
5 Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Rear wheel
12 Rear light
13 Rear guard
14 Kickstand
15 Chain
16 Chain guard
17 Pedal
12345678910111213
14 15 16 17
MY20K08-2_1.0_13.01.2020 8
Overview
3.1 Description
3.1.1 Wheel
The bicycle has two wheels: a front wheel and a
rear wheel.
Figure 2: Visible wheel components – front wheel used as an example
1 Tyre
2 Rim
3 Fork head
4 Fork leg
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of fork leg
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The bicycle either has a classical Dunlop valve, a
Presta valve or a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series.
3.1.2.1 Rigid fork
Rigid forks do not feature suspension. They transfer
the used muscle and motor power to the road to
optimum effect. Bicycles with rigid forks consume
less energy on steep roads and have a greater range
than bicycles with adjusted suspension.
3.1.2.2 Suspension fork
A suspension fork is based either on a steel spring or
air suspension.
Unlike a rigid fork, a suspension fork has two
functions which improve floor contact and comfort:
suspension and damping. The suspension prevents
an impact, such as one caused by a stone lying in the
bicycle's path, from being channelled directly into the
rider's body via the fork. The impact is absorbed by
the suspension system instead. This causes the
suspension fork to compress.
Figure 3: Bicycle without suspension (1) and with suspension (2)
1
2
4
5
8
7
3
9
6
12
MY20K08-2_1.0_13.01.2020 9
Overview
After compressing, the suspension fork returns to
its original position. If there is a damper, it
decelerates movement, preventing the
suspension system from springing back in an
uncontrolled manner and stopping the fork from
vibrating up and down. Dampers which dampen
compressive deflection movements, i.e. a
compression load, are called compression
dampers or compression dashpots.
Dampers which dampen rebound deflection
movements, i.e. a rebound load, are called
rebound dampers or dashpots.
The compression can be disabled in any suspension
fork. A suspension fork will then behave like a rigid
fork.
3.1.2.3 Steel suspension fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6).
Figure 4: Example showing Suntour fork
Other elements: the setting wheel for negative
deflection (9), crown (3), Q-Loc (5), dust seal (4),
fork end (7) and stanchion (8)
1
1
2
3
4
5
6
8
9
7
MY20K08-2_1.0_13.01.2020 10
Overview
3.1.2.4 Air suspension fork
The air suspension fork features air suspension and
a compression damper plus a rebound damper in
some cases.
Figure 5: Example showing Yari fork
You can see these components in the diagram: Air
valve (1), valve cap (2), fork lock (3), quick
release (4) and rebound damper adjuster (5) and
the assembly groups: Air suspension fork (A),
compression damper assembly group (B) and
rebound damper assembly group (C)
3.1.3 Brake system
Every bicycle has a hydraulic brake system. The
brake fluid is in a closed hose system. If the rider
pushes the brake lever, the brake fluid activates
the brake on the wheel.
The bicycle has either:
• a rim brake on the front and rear wheels
• a disc brake on the front and rear wheels or
• a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the bicycle to a
halt quickly and safely in the event of an
emergency.
A
B
C
1
2
3
4
5
A
B
C
MY20K08-2_1.0_13.01.2020 11
Overview
3.1.3.1 Rim brake
Figure 6: Brake system with rim brake in detail – Magura HS22 used as an example
1 Rear wheel rim brake
2 Brake booster
3 Brake lining
4Handlebars with brake lever
5 Front wheel rim brake
Figure 7: Rim brake locking lever, closed (1) and open (2)
The rim brake stops the wheel moving when the
rider pushes the brake lever, causing two brake
linings, positioned opposite one another, to be
pressed onto the rims. The hydraulic rim brake
features a locking lever. The rim brake locking
lever is not marked with any lettering. Only a
specialist dealer may set the rim brake locking
lever.
3.1.3.2 Disc brake
Figure 8: Brake system with disc brake – example
1 Brake disc
2 Brake calliper with brake linings
3Handlebars with brake lever
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 pushed to increase brake
pressure. The brake fluid is used to transfer
pressure through the brake lines to the cylinders
in the brake calliper. The braking force is boosted
1
2
3
4
5
21
1
2
3
4
5
MY20K08-2_1.0_13.01.2020 12
Overview
by a speed reduction and applied to the brake
linings. These apply the brake disc mechanically.
If the brake lever is pushed, the brake linings are
pressed against the brake disc and the wheel
movement is decelerated until it comes to a stop.
3.1.3.3 Back-pedal brake
Figure 9: Brake system with a back-pedal brake – example
1 Rear wheel rim brake
2Handlebars with brake lever
3 Front wheel rim brake
4Pedal
5 Back-pedal brake
The back-pedal brake stops the movement of the
rear wheel when the rider pedals in the opposite
direction to the direction of travel.
5
MY20K08-2_1.0_13.01.2020 13
Overview
3.2 Proper use
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 riding
light, reflectors and other components.
The general laws and the regulations for the
prevention of accidents and environmental
protection in the respective country of use must be
adhered to. All check lists and instructions for
actions in these operating instructions must be
observed. Approved accessories can be installed
by specialist staff.
Each bicycle is assigned a bicycle type, which
determines its proper use, function and area of
use.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are desi-
gned for daily, com-
fortable use. They are
suitable for riding on
public roads.
The legal guardians
of minor riders must
read and understand
these operating
instructions before
putting the bicycle
into use.
The content of these
operating instruc-
tions must be com-
municated to the
riders in an age-
appropriate manner.
The cycles for child-
ren and young adults
are suitable for riding
on public roads. The
size of the cycle must
be checked regularly
for orthopaedic rea-
sons.
A check must be
made at least every
three months to make
sure that the maxi-
mum permitted total
weight is being obser-
ved.
Mountain bikes are
designed for sporting
use. The design cha-
racteristics include a
short wheelbase, a
sitting position with
the rider inclined
towards the front, and
a brake requiring low
actuation force.
A mountain bike is a
piece of sporting
equipment. It requires
an adaptation period
as well as physical fit-
ness. Use requires
the appropriate trai-
ning; 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 exces-
sively and lose con-
trol as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road sur-
face.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is cha-
racterised by its light-
weight structure and
a design which is
stripped to the mini-
mum parts required
for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicy-
cle can be ridden at
high speeds. The
frame design requires
practice to ensure the
ride is able to ride
slowly, apply the
brakes and get on
and off the bike
safely.
The sitting position is
athletic. The strain on
the rider, in particular
the hands and wrists,
arms, shoulders,
neck and back, is
accordingly high. The
sitting position there-
fore requires physi-
cal fitness.
The cargo bike is
suitable for daily
transportation of
loads on public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied
loading conditions
and weight distributi-
ons require special
practice and skill
when braking and
riding in bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
You need to be cau-
tious when riding a
cargo bike. You must
pay attention to the
traffic on public roads
and the condition of
the route accordingly.
The folding bicycle is
suitable for use on
public roads.
A folding bicycle can
be folded up and is
thus suitable for
space-saving trans-
portation, for example
on public transport or
in a car.
The folding function
of the folding bicycle
makes it necessary to
use smaller wheels
and longer brake
cables and Bowden
cables. Therefore, in
case of an increased
load, a reduction in
riding stability and
braking power, dimi-
nished comfort and
reduced durability are
to be expected.
Table 3: Proper use for each bicycle type
MY20K08-2_1.0_13.01.2020 14
Overview
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the bicycle in the following ways:
• when the electrical drive system has been
manipulated
• riding with a damaged or incomplete bicycle
• riding over steps
• riding through deep water
• lending the bicycles to untrained riders
• carrying other people
• riding with excessive baggage
• riding with no hands
• riding on ice and snow
• improper servicing
• improper repair
• tough areas of use, such as professional
competitions
• stunt riding or acrobatics.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking bicy-
cles are not sports
bicycles. If used for
sports, the rider can
expect reduced riding
stability and diminis-
hed comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a guard and
other fittings as spe-
cified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a guard and
other fittings as spe-
cified by national
laws and regulati-
ons before they are
used on public
roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 4: Information on improper use
MY20K08-2_1.0_13.01.2020 15
Overview
3.4 Technical data
3.4.1 Bicycle
3.4.2 Tightening torque
*if there is no other data on the component
Transportation temperature 5 °C - 25 °C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 10 °C - 30 °C
Ideal storage temperature 10 °C - 15 °C
Operating temperature 5°C - 35°C
Work environment temperature 15 °C - 25 °C
Charging temperature 0 °C - 40 °C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 5: Bicycle technical data
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 6: Tightening torque values
MY20K08-2_1.0_13.01.2020 16
Overview
3.5 Environmental requirements
You can be ride the bicycle within a temperature
range between 5 °C and 35 °C. The electric drive
system is limited in its performance outside this
temperature range.
Temperatures under -10 °C and over +60 °C must
be avoided.
You must also keep within the following
temperature ranges:
The nameplate contains symbols for the bicycles'
area of use. Check what roads and paths you may
use before you ride the bicycle for the first time.
Optimal operating temperature 22 °C - 26 °C
Transportation temperature -10 °C - 50 °C
Storage temperature -10 °C - 50 °C
Work environment temperature 15 °C - 25 °C
Charging temperature 0 °C - 40 °C
Table 7: Bicycle technical data
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Suitable for tarmac-
ked and paved
roads.
Suitable for tarmac-
ked and paved
roads.
Suitable for tarmac-
ked and paved
roads.
Suitable for tarmac-
ked and paved
roads.
Suitable for tarmac-
ked and paved
roads.
Suitable for tarmac-
ked roads, cycle
paths and firm gravel
paths and roads, and
longer sections with
moderate slopes and
jumps up to 15 cm.
Suitable for tarmac-
ked roads, cycle
paths and firm gra-
vel paths and roads,
and longer sections
with moderate slopes
and jumps up to
15 cm.
Suitable for tarmac-
ked roads, cycle
paths and easy to
demanding off-road
riding, sections with
moderate slopes
and jumps up to
61 cm.
Suitable for tarmac-
ked roads, cycle
paths and firm gra-
vel paths and roads,
and longer sections
with moderate
slopes and jumps up
to 15 cm.
Suitable for tarmac-
ked roads, cycle
paths and easy to
demanding off-road
riding, limited
downhill use and
jumps up to
122 cm.
Suitable for tarmac-
ked roads, cycle
paths and easy to
extremely difficult
off-road riding, unli-
mited downhill use
and any jumps.
Table 8: Area of use
MY20K08-2_1.0_13.01.2020 17
Overview
The bicycle is unsuitable for the following areas of use:
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-
road or perform
jumps over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never ride downhill
or perform jumps
over 61 cm.
Never traverse
extremely difficult
off-road terrain or
perform jumps over
122 cm.
MY20K08-2_1.0_13.01.2020 18
Overview
3.6 Description of controls and
screens
3.6.1 Handlebars
Figure 10: Detailed view of bicycle from rider position
1 Rear brake lever
2 Headlight
3Bell
4 Front brake lever
5Shifter
6Shifter
1
2
5
3
4
6
MY20K08-2_1.0_13.01.2020 19
Transporting and storing
4 Transporting and storing
4.2 Transporting
Transport the bicycle in a dry, clean position where it is protected from direct sunlight.
4.3 Storing
Store the bicycle in a clean, dry place where it is protected from direct sunlight. Do not store outdoors
to ensure a long service life.
Temperatures under -10 °C or over +60 °C must
generally be avoided. Storage at about 20 °C is
beneficial to a long service life.
4.1 Physical transport
characteristics
4.1.1 Dimensions during transportation
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the service portal.
4.1.2 Transport weight
There was no information relating to transport
weight at the time of going to press. You'll find
the information in the latest operating
instructions on the service portal.
4.1.3 Designated handles/lifting points
The box does not have any handles.
Notice
When shipping the bicycle, we recommend
that you have the specialist dealer partially
dismantle the bicycle and place it in the proper
packaging.
Optimum storage temperature for the
bicycle 20 °C
Table 9: Storage temperature for batteries and the bicycle
MY20K08-2_1.0_13.01.2020 20
Assembly
5 Assembly
Assemble the bicycle in a clean and dry
environment.
The work environment temperature should be
between 15 °C and 25 °C.
The fitting stand used must be approved for a
maximum weight of at least 25 kg.
5.1 Required tools
The following tools are required to assemble the
bicycle:
5.2 Unpacking
The packaging has to be disposed of in accordance with the regulations of the authorities.
5.2.1 Scope of delivery
The bicycle is fully 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 operating instructions.
5.3 Commissioning
Only trained specialist staff may perform initial
commissioning since putting the bicycle into use
requires special tools and specialist knowledge.
Experience has shown that a bicycle which has
not yet been sold is automatically handed to
customers as soon as it appears ready to ride.
For this reason, every bicycle must be prepared, so it is fully ready for use immediately after being
assembled.
The assembly report (see Section 11.2) describes all safety-relevant inspections, tests and
maintenance tasks for the bicycle in a separate list. All assembly work must be completed to ensure the
bicycle is ready to ride.
Complete an assembly report for quality assurance purposes.
Injury to the eyes
Problems may arise if the settings are not made
to components correctly and you may sustain
serious injuries as a result.
Always wear safety glasses to protect your
eyes during assembly.
WARNING
!
•Knife
• Hexagon socket spanner 2 (2.5 mm, 3 mm,
4 mm, 5 mm, 6 mm and 8 mm)
• Torque wrench with working range between
5and 40Nm
• Twelve-point square socket T25
• Ring spanner (8 mm, 9 mm, 10 mm), 13 mm,
14 mm and 15 mm) and
• Cross, flat head and ordinary screwdriver.
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
!
MY20K08-2_1.0_13.01.2020 21
Assembly
5.3.1 Installing the wheel in the Suntour fork
5.3.1.1 Screw-on axle (15 mm)
Only applies to Suntour forks with 15 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 11: Fully inserting the axle
2Tighten the axle to 8–10 Nm with a 5 mm
hexagon socket spanner.
Figure 12: Tightening the axle
3Insert the securing screw on the non-drive
side.
Figure 13: Pushing the quick release lever into the axle
4Tighten the securing screw with a 5 mm
hexagon socket spanner to 5–6 Nm.
MY20K08-2_1.0_13.01.2020 22
Assembly
The lever is mounted.
Figure 14: Tightening the securing screw
5.3.1.2 Screw-on axle (20 mm)
Only applies to Suntour forks with 20 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 15: Tightening the inserted axle
2Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 16: Tightening the securing clip
5.3.1.3 Quick release axle
Only applies to Suntour forks with screw-on axle
CAUTION
!
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.
MY20K08-2_1.0_13.01.2020 23
Assembly
1Insert the axle into the hub on the drive side.
Figure 17: Pushing the axle into the hub
Crash caused by faulty or incorrectly
installed quick release axle
The brake disc becomes very hot during
operation. Parts of the quick release axle may
become damaged as a result. The quick release
axle becomes loose. This will cause a crash with
injuries.
The quick release axle and the brake disc
must be opposite one another.
Crash caused by incorrectly set quick release
axle
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release axle may
break. This will cause a crash with injuries.
Never fasten a quick release axle with a tool,
such as a hammer or pliers.
MY20K08-2_1.0_13.01.2020 24
Assembly
2Tighten the axle with the red handle.
Figure 18: Tightening the axle
3Push the quick release lever into the axle.
Figure 19: Pushing the quick release lever into the axle
4Turn the quick release lever.
The lever is secured.
Figure 20: Securing the lever
MY20K08-2_1.0_13.01.2020 25
Assembly
5Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 21: Perfect position for the clamping lever
6Use 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
7Check the quick release lever position and
clamping force.
Figure 22: Adjusting the quick release clamping force
MY20K08-2_1.0_13.01.2020 26
Assembly
5.3.1.4 Quick release
Only applies to Suntour forks with quick release 1Before installing, ensure that the quick release
flange is extended. Open the lever fully.
Figure 23: Open and closed flange
2Push in the quick release until you can hear a
click. Make sure that the flange is extended.
Figure 24: Pushing the quick release in
Crash caused by unfastened quick release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Never fit a defective quick release.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release may break.
This will cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY20K08-2_1.0_13.01.2020 27
Assembly
3Adjust tensioning with half-open clamping
lever until the flange reaches the fork end.
Figure 25: Adjusting the clamping
4Fully close the quick release. Check that the
quick release is firmly in place and adjust it on
the flange if necessary.
The lever is secured.
Figure 26: Closing the quick release
5.3.2 Installing the wheel in the FOX fork
5.3.2.1 Quick release (15 mm)
Only applies to FOX forks with 15 mm screw-on axle
The procedure for installing the 15 x 100 mm and
15 x 110 mm quick releases is the same.
1Place the front wheel in the fork ends of the
fork. Push the axle through the fork end on the
non-drive side and hub.
Figure 27: Pushing the quick release in
2Open the axle lever.
3Turn the axle five to six complete revolutions
clockwise into the axle nut.
4Close the quick release lever. The lever must
be tensioned to the point that it leaves a mark
on your hand.
MY20K08-2_1.0_13.01.2020 28
Assembly
5The lever must be 1 to 20 mm ahead of the fork
leg in the closed position.
Figure 28: Spacing between lever and fork leg
The quick release must be adjusted if the lever
is tensioned inadequately or too strongly when
closed in the recommended position (1 to
20 mm in front of the fork).
Setting the quick releases
Figure 29: Structure of quick release from rear with (1) axle nut lock and (5) axle nut
1Record the axle setting value (4) indicated by
the directional arrow (3).
2Loosen the axle nut securing screw (2) with a
2.5 mm hex key by approx. four revolutions,
but do not remove the screw completely.
3Turn the quick release lever to the open
position and loosen the axle by approx. four
revolutions.
4Press the axle inward from the side of the open
lever. This pushes out the axle nut securing
screw so that you can turn it out of the way.
5Push the axle further forward and turn the axle
nut clockwise to increase the lever tension or
anti-clockwise to reduce the lever tension.
6Reinsert the axle nut lock and tighten the screw
to 0.9 Nm (8 in-lb).
7Repeat the steps for installing the axle to check
proper installation and correct adjustment.
1-20 mm
1
2
3
45
MY20K08-2_1.0_13.01.2020 29
Assembly
5.3.2.2 Kabolt axle
Only applies to FOX forks with Kabolt axles
The procedure for installing the 15 x 100 mm and
15 x 110 mm Kabolt axles is the same.
1Place the front wheel in the fork ends of the
fork. Push the Kabolt axle through the fork end
on the non-drive side and hub.
Figure 30: Pushing the Kabolt axle in
2Tighten the Kabolt axle screw to 17 Nm
(150 in-lb) with a 6 mm hex key.
5.3.3 Checking the stem and handlebars
5.3.3.1 Checking connections
1Stand in front of the bicycle to check whether
the handlebars, fork steerer and fork shaft are
firmly attached to one another. Clamp the front
wheel between your legs. Grasp the handlebar
grips.
2Try to twist the handlebars towards the front
wheel.
The stem must not move or twist.
MY20K08-2_1.0_13.01.2020 30
Assembly
5.3.3.2 Firm hold
1Place your entire body weight on the
handlebars with the quick release lever closed
to check that the stem is firmly in place.
The handlebars shaft must not move
downwards in the fork steerer.
2If the handlebars shaft should move in the fork
steerer, increase the quick release lever
tensioning. To do so, turn the knurled nut
slightly in a clockwise direction with the quick
release lever open.
3Close the lever and check the stem is firmly in
position.
5.3.3.3 Checking the headset backlash
1To check the handlebar headset backlash,
close the quick release lever on the stem.
2Place the fingers of one hand on the upper
headset cup. Pull the front wheel brake with the
other hand and try to push the bicycle
backwards and forwards.
3The headset cup halves must not move
towards one another while you are doing this.
Note that there may be noticeable backlash
due to worn-out bearing bushes or brake lining
backlash in suspension forks and disc brakes.
4If there is headset backlash in the steering
headset, you must adjust it as soon as
possible; otherwise, the headset will become
damaged. You must make the adjustment as
described in the stem manual.
5.4 Selling bicycles
Complete bike pass on the Operating instructions cover.
Adjust the bicycle to the rider; see Section 6.3.
Set the stand and the shifter.
Instruct the operator or rider on how to use all the bicycle’s functions.
MY20K08-2_1.0_13.01.2020 31
Operation
6 Operation
6.1 Risks and hazards
6.1.1 Personal protective equipment
It is recommended that you wear a suitable
cycling helmet, sturdy footwear and typical, close-
fitting, reflective cycling clothing.
Injuries and death caused by other road users
Other road users such as buses, trucks, cars or
pedestrians often underestimate the speed of
bicycles. Other road users frequently do not see
bicycles either. This may lead to an accident with
serious injuries or even death.
Wear a cycling helmet and high-visibility,
reflective clothing.
Always take a defensive approach to riding.
Avoid the blind spots of vehicles turning off.
Reduce speed as a precaution when other
road users turn right.
Crash caused by loose clothing
Shoe laces, scarves and other loose items may
become entangled in the spokes on the wheels
and on the chain drive. This may cause a crash
with injuries.
Wear sturdy footwear and close-fitting
clothing.
Crash caused by soiling
Heavy soiling can impair the bicycle's functions,
such as the brake functions. This may cause a
crash with injuries.
Remove coarse soiling before riding.
Crash caused by poor road conditions
Loose objects, such as branches and twigs, may
become caught in the wheels and cause a crash
with injuries.
Be aware of the road conditions. Ride slowly
and brake in good time.
WARNING
!
CAUTION
!
Notice
Heat or direct sunlight can cause the tyre pressure
to increase above the permitted maximum
pressure. This can destroy the tyres.
Never park the bicycle in the sun.
On hot days, regularly check the tyre pressure
and adjust it as necessary.
When riding downhill, high speeds may be
reached. The bicycle is only engineered for
exceeding a speed of 25 km/h briefly. The tyres in
particular can fail if exposed to a continuous load.
Decelerate the bicycle with the brakes if higher
speeds than 25 km/h are reached.
Notice
Moisture penetrating at low temperatures may
impair individual functions due to the open
structural design.
Always keep the bicycle dry and free from
frost.
If the bicycle is to be used at temperatures
below 3 °C, the specialist dealer must carry
out an inspection and prepare it for winter use.
Off-road riding subjects the joints in the arms to
severe strain.
Take a break from riding every 30 to
90 minutes, depending on the road surface
conditions
MY20K08-2_1.0_13.01.2020 32
Operation
6.2 Instruction and customer service
Your supplying specialist dealer will provide
customer service. Contact details can be found on
the bike pass for these operating instructions. The
specialist dealer will explain all the bicycle
functions to you in person, this being when the
specialist dealer hands over the bicycles at the
latest. These operating instructions are provided
to you with every bicycle, so that you can consult
them at a later stage.
Your specialist dealer will also be happy to assist
you in the future whether you require
maintenance, conversion or repair.
6.3 Adjusting the bicycle
Only a correctly adjusted bicycle will guarantee
the desired ride comfort and health-promoting
activity. Therefore adjust the saddle, the
handlebars and the suspension to your body and
your preferred riding style before the first ride.
6.3.1 Adjusting the saddle
6.3.1.1 Adjusting the saddle tilt
The saddle tilt must be adjusted to the seat height,
the saddle and handlebar position, and the saddle
shape to ensure an optimum fit. The seating
position can be optimised in this way if needed.
First, readjust the saddle after finding the
handlebar position you prefer.
Place the saddle tilt in the horizontal position to adjust the bicycle to your needs for the first time.
Figure 31: Horizontal saddle tilt
6.3.1.2 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.
1Climb onto the bicycle.
2Place your heel on the pedal and extend your
leg, so that the pedal is at the lowest crank
rotation point.
The rider sits straight on the saddle if the seat
is at an optimum height. If this is not the case,
Crash caused by incorrectly adjusted torques
If a screw is fastened too tightly, it may break. If a
screw is not fastened enough, it may loosen. This
will cause a crash with injuries.
Always observe the indicated torques on the
screw or in the operating instructions.
CAUTION
!
MY20K08-2_1.0_13.01.2020 33
Operation
you can adjust the length of the seat post to
your needs.
Figure 32: Optimal saddle height
MY20K08-2_1.0_13.01.2020 34
Operation
6.3.1.3 Adjusting the seat height with quick
release
1Open the quick release on the seat post to
change the seat height (1). To do so, push the
clamping lever away from the seat post (3).
Figure 33: Opening the seat post quick release
2Set the seat post at the required height.
Figure 34: Detailed view of the seat post – examples of the minimum insertion depth marking
3To close it, push the seat post clamping lever as
far as it will go into the seat post (2).
4Check the clamping force of quick releases.
6.3.1.4 Height-adjustable seat post
Only applies to bicycles with this equipment
Preparing
1When 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.
Lowering the saddle
Figure 35: The seat post lever can be installed either on the left (1) or right (2) side of the handlebars
1Press your hand down on the saddle or sit on
the saddle to lower the saddle.
2Press the seat post lever and hold it down.
3
4
5
1
2
3
Crash caused by an excessively high seat post
setting
A seat post with is set too high will cause the seat
post or the frame to break. This will cause a crash
with injuries.
Do not pull the seat post out of the frame
beyond the minimum insertion depth marking.
CAUTION
!
3
4
2
1
e
tiert w
se Position zur Be
aber in einem spätere
ochmals montieren.
Sie den mitgelieferten Winkel mit de
orrichtung und stecken Sie die Hülle in die
nvorrichtung.
der
Remotehebel
5
Oder
28
12
MY20K08-2_1.0_13.01.2020 35
Operation
3Release the seat post lever once you have
reached the required height.
Raising the saddle
1Press the seat post lever and hold it down.
2Remove any pressure from the saddle.
3Release the seat post lever once you have
reached the required height.
MY20K08-2_1.0_13.01.2020 36
Operation
6.3.1.5 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
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.
1Climb onto the bicycle.
2Place the pedals into the vertical position with
your feet.
The rider is sitting in the optimal sitting position if
the knee cap perpendicular line runs through the
pedal axle.
3.1If the perpendicular line crosses behind the
pedal, bring the saddle forward.
3.2If the perpendicular line crosses in front of the
pedal, bring the saddle back.
4Move the saddle within its permitted
displacement range only (marked on the
saddle stay).
Figure 36: Knee cap perpendicular line
90°
The handlebar settings must only be adjusted
while the bicycle is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the
maximum tightening torque for the clamping
screws of the handlebars.
MY20K08-2_1.0_13.01.2020 37
Operation
6.3.2 Adjusting the handlebars 6.3.3 Adjusting the stem
6.3.3.1 Adjusting the height of the handlebars
1Open the stem clamping lever.
Figure 37: Open (2) and closed (1) stem clamping lever – by.schulz speedlifter used as an example
2Pull the stem clamping lever upwards while
swivelling the handlebars into the required
position.
You feel the locking lever click into place.
Figure 38: Pulling locking lever upwards – by.schulz speedlifter used as an example
3Pull out the handlebars to the required height. 4Close the stem clamping lever.
6.3.3.2 Adjusting the quick release clamping
force
If the handlebar clamping lever stops before reaching its end position, unscrew the knurled nut.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
Crash caused by loose stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the quick release
system are firmly in position after the first two
hours of riding.
CAUTION
!
1
2
MY20K08-2_1.0_13.01.2020 38
Operation
Tighten the knurled nut on the seat post if the seat post clamping lever's clamping force is not effective
enough.
If you are unable to set the clamping force, the specialist dealer will need to check the quick release.
6.3.4 Setting the brake
The brake lever grip distance can be adjusted to
ensure that it can be reached more easily. The
pressure point can also be adjusted to the rider's
preferences.
Contact your specialist dealer if there is no
description of your brake below.
MY20K08-2_1.0_13.01.2020 39
Operation
6.3.4.1 Setting the grip distance on a
Magura HS33 brake lever
Only applies to bicycles with this equipment
You can adjust the brake lever position (grip
distance) to your requirements. Such adjustment
does not affect the pressure point or the position
of the brake linings.
Use a T25 TORX® wrench to turn the setting
screw (1) to adjust the grip distance.
Figure 39: Setting the grip distance on a Magura HS33 brake lever
Turn the setting screw anti-clockwise towards minus (–).
The brake lever moves closer to the handlebar
grip.
Turn the setting screw clockwise towards plus (+).
The brake lever moves away from the
handlebar grip.
1
2
MY20K08-2_1.0_13.01.2020 40
Operation
6.3.4.2 Setting the grip distance on a
Magura HS22 brake lever
Only applies to bicycles with this equipment
You can adjust the brake lever position (grip
distance) to your requirements.
Use a T25 TORX® wrench to turn the setting
screw (1) to adjust the grip distance.
Figure 40: Setting the grip distance on a Magura HS33 brake lever
Push the brake lever gently and hold.
Move the slider (2) outwards (–) to Position II or III.
The brake handle moves closer to the
handlebars.
The brake linings move closer to the rim.
The pressure point activates sooner.
Move the slider inwards (+) to Position II or I.
The brake lever moves away from the
handlebars.
The brake linings move away from the rim.
The pressure point activates later.
6.3.4.3 Setting the grip distance on a
Crash caused by incorrectly set grip distance
If brake cylinders are set or installed incorrectly,
braking power may be lost completely at any time.
This may cause a crash with serious injuries.
Once the grip distance has been set, check the
position of the brake cylinder. Correct if
necessary.
WARNING
!
MY20K08-2_1.0_13.01.2020 41
Operation
Magura disc brake lever
Only applies to bicycles with this equipment
You can adjust the brake lever position (grip
distance) to your requirements. Such adjustment
does not affect the pressure point or the position
of the brake linings.
Use a T25 TORX® wrench to turn the setting
screw (1) to adjust the grip distance.
Figure 41: Setting the grip distance on a Magura disc brake lever
Turn the setting screw/twist knob (5) anti-clockwise towards minus (–).
The brake lever moves closer to the handlebar
grip.
Turn the setting screw clockwise towards plus (+).
The brake lever moves away from the
handlebar grip.
Crash caused by incorrectly set grip distance
If brake cylinders are set incorrectly or installed
wrongly, the braking power may be lost at any
time. This may cause a crash with injuries.
Ensure that the fully applied brake lever is at a
minimum distance of 20 mm from the
handlebars (4).
WARNING
!
MY20K08-2_1.0_13.01.2020 42
Operation
6.3.4.4 Setting 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 42: Using the twist knob (1) to adjust the pressure point
6.3.5 Retracting the brake linings
Disc brakes require wearing-in time. The braking
force increases over time. You therefore need to be
aware that the braking force may increase during the
wearing-in period. The same happens after brake
pads or discs are replaced.
1Accelerate bicycle to about 25 km/h.
2Brake bicycle until it comes to a halt.
3Repeat process 30–50 times.
The disc brake is retracted and provides
optimal braking power.
6.3.6 Adjusting the Suntour fork
Only applies to bicycles with this equipment
Brake failure due to incorrect setting
If the pressure point is set with brakes where the
brake linings and brake disc have reached their
wear limit, the brakes may fail and cause an
accident with injury.
Before you set the pressure point, ensure that
the brake linings and brake disc have not
reached their wear limit.
WARNING
!
1
Crash caused by incorrectly set suspension
If the suspension is set incorrectly, the fork may
become damaged, so that problems may occur
when steering. This will cause a crash with
injuries.
Never ride the bicycle without air in the air
suspension fork.
Never use the bicycle without adjusting the
suspension fork to the rider's weight.
Notice
CAUTION
!
MY20K08-2_1.0_13.01.2020 43
Operation
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.
6.3.6.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection is between 15% (hard) and 30% (soft)
of the total fork deflection.
6.3.6.2 Adjusting the steel suspension fork
negative deflection
Only applies to bicycles with this equipment
You can adjust the tensioning in the fork spring to
the rider's weight and their preferred riding style.
This reduces the negative deflection in the fork.
Figure 43: Negative deflection setting wheel on the suspension fork crown
1You will find the negative deflection setting
wheel beneath the plastic cover on the crown.
Remove the plastic cover.
Turn the negative deflection setting wheel in a
clockwise direction to increase the spring pre-
tensioning.
Turn the negative deflection setting wheel in
an anti-clockwise direction to decrease the
spring pre-tensioning.
You will have made the ideal setting when the
shock absorber deflects 3 mm when subject to
the rider's weight.
3Replace the plastic cover on the crown after
making the setting.
6.3.6.3 Adjusting the air suspension fork
negative deflection
Only applies to bicycles with this equipment
The air valve is located beneath the valve cap on the crown of the left-hand shock absorber. Unscrew
the valve cap.
Figure 44: Screw caps in different designs
Settings on the chassis change riding
performance significantly. You need to get used
to the bicycle and break it in to prevent accidents.
MY20K08-2_1.0_13.01.2020 44
Operation
1Attach a high-pressure damper pump to the air
valve.
2Pump air suspension fork to the required
pressure. Observe the levels in the Suntour
filling pressure table. Never exceed the
recommended maximum air pressure.
3Detach high-pressure damper pump.
4Measure the distance between the crown and
the dust seal. This distance is total deflection
of the fork.
5Push a temporarily attached cable tie
downward against the dust seal.
6Put on your normal cycling clothing, including
luggage.
7Sit on the bicycle in your usual riding position
and support yourself against an object, such as
a wall or tree.
8Get off the bicycle without allowing it to deflect.
9Measure distance between the dust seal and
the cable tie.
This measurement is the negative deflection.
The recommended value is between 15%
(hard) and 30% (soft) of the total fork
deflection.
10 Increase or reduce air pressure until you have
reached the desired negative deflection.
If the negative deflection is correct, turn the
valve cap in a clockwise direction.
If you are unable to achieve the desired
negative deflection, an internal adjustment
may be needed. Contact your specialist dealer.
6.3.6.4 Adjusting the air suspension fork
rebound
Only applies to bicycles with this equipment
The rebound setting depends on the negative
deflection setting: A higher negative deflection
requires a lower rebound setting.
1Turn the Suntour rebound screw in a
clockwise direction to the closed position until
it stops.
Figure 45: Suntour rebound screw (2), fork (1)
2Turn the Suntour rebound screw slightly in an
anti-clockwise direction.
3Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward. Bottoming out refers to when the fork
rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You can hear and feel a slight impact
when this happens.
6.3.7 Adjusting the FOX fork
Only applies to bicycles with this equipment
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
Maximum air
pressure
150 psi 180 psi
Table 10: Suntour filling pressure table for air forks
1
2
CAUTION
!
MY20K08-2_1.0_13.01.2020 45
Operation
The adjustment shown here represents a basic
setting. The basic setting can be adjusted to the
riding surface and personal preferences.
6.3.7.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection is between 15% (hard) and 20% (soft)
of the total fork deflection depending on
preferences and how the bicycle is used.
When adjusting the negative deflection, ensure
that each compression adjuster is in an open
position, i.e. each compression adjuster has been
turned in an anti-clockwise direction until it goes
no further.
The pressure is to be measured at an ambient
temperature of 21 to 24 °C.
1The air valve is located beneath a blue valve
cap on the crown of the left-hand shock
absorber. Unscrew the valve cap in an anti-
clockwise direction.
2Attach a high-pressure damper pump to the air
valve.
3Pump the suspension fork to the required
pressure. Observe the levels in the FOX filling
pressure table. Never exceed the maximum
air pressure or fall below the minimum air
pressure recommended in the table.
Crash caused by incorrectly set suspension
If the suspension is set incorrectly, the fork may
become damaged, so that problems may occur
when steering. This will cause a crash with
injuries.
Never ride the bicycle without air in the air
suspension fork.
Never use the bicycle without adjusting the
suspension fork to the rider's weight.
Notice
Settings on the chassis change riding
performance significantly. You need to get used
to the bicycle and break it in to prevent accidents.
It is recommended to note down the determined
negative deflection and rebound levels. This way,
the levels can be used as a starting point for
subsequent, optimised settings and as a
safeguard against unintentional changes.
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
Table 11: FOX filling pressure table for air fork
MY20K08-2_1.0_13.01.2020 46
Operation
4Detach high-pressure damper pump.
5Measure the distance between the crown and
the fork's dust wiper. This distance is total
deflection of the fork.
6Push the O-ring downwards against the fork's
dust wiper. If there is no O-ring, attach a cable
tie to the stanchion temporarily.
7Put on your normal cycling clothing, including
luggage.
8Sit on the bicycle in your usual riding position
and support yourself against an object, such as
a wall or tree.
9Get off the bicycle without the suspension fork
deflecting.
10 Measure the distance between the dust wiper
and the O-ring or cable tie.
This measurement is the negative deflection.
The recommended value is between 15%
(hard) and 20% (soft) of the total fork
deflection.
11 Increase or reduce the air pressure until you
have reached the desired negative deflection.
If the negative deflection is correct, turn the
blue valve cap in a clockwise direction.
6.3.7.2 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. A higher
negative deflection requires a lower rebound
setting.
1Turn the FOX rebound adjuster in a clockwise
direction to the closed position until it stops.
Figure 46: FOX rebound adjuster (1) on the fork end
2Turn the FOX rebound adjuster slightly in an
anti-clockwise direction.
3Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward. Bottoming out refers to when the fork
rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You can hear and feel a slight impact
when this happens.
Maximum air
pressure
120 psi (8.3 bar) 120 psi (8.3 bar)
Table 11: FOX filling pressure table for air fork
If you are unable to achieve the desired negative
deflection, internal settings may need to be
changed. Contact your specialist dealer.
1
MY20K08-2_1.0_13.01.2020 47
Operation
6.4 Accessories
We recommend a parking stand into which either
the front wheel or rear wheel can be inserted
securely for bicycles which do not have a
kickstand. The following accessories are
recommended:
*System components are matched to the pannier
rack and provide sufficient stability due to special
transmission of force.
**System components are matched to the drive
system.
6.4.1 Child seat The specialist dealer will advise on choosing a
suitable child seat system for the child and the
bicycle.
The specialist dealer must install the child seat the
first time to ensure that it is safely fitted.
When installing a child seat, the specialist dealer
makes sure that the seat and the fastening
mechanism for the seat are suitable for the bicycle
and that all components are installed and firmly
fastened. The dealer will also ensure that shift
cables, brake cables, hydraulic and electrical
cables are adjusted as necessary, the rider has
optimum freedom of movement and the bicycle's
maximum permitted total weight is adjusted.
The specialist dealer will provide instruction on
how to handle the bicycle and the child seat.
Description Article number
Protective cover for electrical
components 080-41000 ff
Panniers,
system component* 080-40946
Rear wheel basket
system component* 051-20603
Bicycle box
system component* 080-40947
Parking stand
universal stand XX-TWO14B
Table 12: Accessories
Crash caused by incorrect child seat
The pannier rack and down tube are unsuitable
for mounting child seats and may break. Such an
incorrect position may cause a crash with serious
injuries for the rider and the child.
Never attach a child seat to the saddle,
handlebars or down tube.
Crash caused by improper handling
Using a child seat changes a bicycle’s riding
performance and stability 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.
WARNING
!
CAUTION
!
Risk of crushing due to exposed springs
The child may crush his/her fingers on exposed
springs or open mechanical parts of the saddle or
the seat post.
Never install saddles with exposed springs if a
child seat is being used.
Never install seat posts with suspension with
open mechanical parts or exposed springs if a
child seat is being used.
Notice
Observe the legal regulations on the use of
child seats.
Observe the operating and safety instructions
for the child seat system.
Never exceed the maximum permitted total
weight.
CAUTION
!
MY20K08-2_1.0_13.01.2020 48
Operation
6.4.2 Bicycle trailer A bicycle which is approved for towing a trailer is
equipped with the relevant information sign. You
may only use bicycle trailers with a support load
and weight which do not exceed the permitted
values.
Figure 47: Trailer sign
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
6.4.3 Pannier rack
The specialist dealer will advise on choosing a
suitable pannier rack.
The specialist dealer must install the pannier rack
the first time to ensure that it is safely fitted.
When installing a pannier rack, the specialist
dealer makes sure that the fastening mechanism
is suitable for the bicycle and that all components
are installed and firmly fastened. The dealer will
also ensure that shift cables, brake cables,
hydraulic cables and electrical cables are
adjusted as necessary, the rider has optimum
freedom of movement and the bicycle's maximum
permitted total weight adjusted.
The specialist dealer will provide instruction on
how to handle the bicycle and the pannier rack.
Crash caused by brake failure
The brake will be weaker if the trailer load is
excessive. The long braking distance can cause a
crash or an accident and injuries.
Never exceed the specified trailer load.
Notice
The operating and safety instructions for the
trailer system must be observed.
The statutory regulations on the use of bicycle
trailers must be observed.
Only use type-approved coupling systems.
CAUTION
!
MY20K08-2_1.0_13.01.2020 49
Operation
6.5 Before each ride 6.6 Check list before each ride
Check the bicycle before each ride.
Take the bicycle out of service if you spot any
anomalies.
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 the frame. This may cause a crash
with injuries.
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 a crash with injuries.
Remove the bicycle from service immediately
if there are any signs of material fatigue. Have
the specialist dealer check the state.
Have the specialist dealer carry out a basic
inspection regularly. During the inspection, the
specialist dealer 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
!
Check that the bicycle is complete.
Check the battery is firmly in place.
Check that the lighting, reflector and brake, for instance,
are sufficiently clean.
You must check that the mudguards, the pannier rack and
the chain guard are securely installed.
Check that the front and rear wheels run true. This is
particularly important if the 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, push the brake levers
while stationary to check whether resistance is generated
in the usual brake lever position. The brake must not lose
any brake fluid.
Check that the riding light is working.
Check for unusual noises, vibrations, smells, staining,
deformation, cracks, scores, abrasion and wear. This
indicates material fatigue.
Inspect suspension system for cracks, dents, bumps, parts
or leaking oil. Look at concealed sections on the 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.
Check that the ABS indicator lamp lights up correctly on
bicycles with an ABS system.
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Operation
6.7 Using the kickstand
6.7.1 Raising the kickstand
Use your foot to raise the kickstand completely
before setting off.
6.7.1.1 Parking the bicycle
Use your foot to lower the kickstand completely
before parking.
Park the bicycle carefully and check that it is
stable.
6.8 Using the pannier rack
Crash caused by a lowered kickstand
There is a risk of crashing if riding with the
kickstand lowered.
Raise the kickstand completely before setting
off.
Notice
The bicycle's force of weight may cause the
kickstand to sink into soft ground, possibly
causing the bicycle to topple over as a result.
The bicycle must be parked on firm, level
ground only.
It is particularly important to check that the
bicycle is stable when it is equipped with
accessories or loaded with baggage.
CAUTION
!
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 a crash with injuries.
You should practice how to use a loaded
pannier rack safely and reliably before using
the bicycle in public spaces.
CAUTION
!
CAUTION
!
MY20K08-2_1.0_13.01.2020 51
Operation
Distribute the baggage as evenly as possible
between the left- and right-hand side.
We recommend the use of panniers and
baggage baskets.
Crash caused by unsecured baggage
Loose or unsecured objects on the pannier rack,
e.g. belts, may become caught in the rear wheel.
This may cause a crash with injuries.
Objects which are fastened to the pannier rack
may cover the reflectors and the riding light. The
bicycle may be overseen on public roads. This
may cause a crash with injuries.
Secure any objects which are attached to the
pannier rack sufficiently.
Objects fastened to the pannier rack must
never cover the reflectors, the headlight or the
rear light.
Crushing the fingers in the spring flap
The spring flap on the pannier rack operates with
a high clamping force. There is a risk of crushing
the fingers.
Never allow the spring flap to snap shut in an
uncontrolled manner.
Be careful where you position your fingers
when closing the spring flap.
Notice
The maximum load bearing capacity is indicated
on the pannier rack.
Never exceed the maximum permitted total
weight when packing the pannier.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
MY20K08-2_1.0_13.01.2020 52
Operation
6.9 Brake
The drive force of the motor is shut off during the
ride as soon as the rider no longer pedals. The
drive system does not switch off when braking.
In order to achieve optimum braking results, do not pedal while braking.
Crash caused by brake failure
Oil or lubricant on the brake disc in a disc brake
or on the rim of a rim brake can cause the brake
to fail completely. This may cause a crash with
serious injuries.
Never allow oil or lubricant to come into
contact with the brake disc or brake linings or
on the rim of a rim brake.
If the brake linings have come into contact with
oil or lubricant, contact a dealer or a workshop
to have the components cleaned or replaced.
If the brakes are applied continuously for a long
time (e.g. while riding downhill for a long time),
the fluid in the brake system may heat up. This
may create a vapour bubble. This will cause air
bubbles or any water contained in the brake
system to expand. This may suddenly make the
lever travel wider. This may cause a crash with
serious injuries.
Release the brake regularly when riding
downhill for a longer period of time.
Amputation due to rotating brake disc
The brake disc in disc brakes is so sharp that it
can cause serious injuries to fingers if they are
inserted into the brake disc openings.
Always keep fingers well away from the
rotating brake discs.
Burns caused by heated brake
The brakes may become very hot during
operation. There is a risk of burns or fire in case
of contact.
Never touch the components of the brake
directly after the ride.
WARNING
!
CAUTION
!
Crash caused by wet conditions
The tyres may slip on wet roads. In wet conditions
you must also expect a longer braking distance.
The braking sensation differs from the usual
sensation. This can cause loss of control or a
crash, which may result in injuries.
Ride slowly and brake in good time.
Crash caused by incorrect use
Handling the brake improperly can lead to loss of
control or crashes, which may result in injuries.
Shift your body weight backwards and down as
far as possible.
Practise braking and emergency braking
before the bicycle is used in public spaces.
Never use the bicycle if you can feel no
resistance when pushing 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 the brake does not
work properly. Consult a specialist dealer.
CAUTION
!
MY20K08-2_1.0_13.01.2020 53
Operation
6.9.1 Using the brake lever
Figure 48: Front (2) and rear (1) brake lever – Shimano brake used as an example
Push the left-hand brake lever to apply the front wheel brake.
Push the right-hand brake lever to apply the rear wheel brake.
6.9.2 Using the back-pedal brake
Only applies to bicycles with this equipment
1Move pedals a little beyond the 3 o'clock and
9 o'clock position.
2Pedal in the opposite direction to the direction
of travel until the desired speed has been
reached.
6.10 Suspension and damping
6.10.1 Adjusting the compression in the
Suntour fork
Only applies to bicycles with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the fork to suit changes in terrain. It
is intended for adjustments made during the ride.
1
2
MY20K08-2_1.0_13.01.2020 54
Operation
Figure 49: Suntour compression adjuster with OPEN (1) and LOCK (2) positions
Compression damping is lowest in the OPEN position, making the fork feel softer.
Use the lock position if you want the fork to feel stiffer and you are riding on soft ground.
The positions between OPEN and LOCK provide fine adjustment of compression damping.
We recommend setting the compression adjuster
to the OPEN position first.
6.10.2 Adjusting the compression in the
Fox fork
Only applies to bicycles with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the fork to suit changes in terrain. It
is intended for adjustments made during the ride.
1
2
MY20K08-2_1.0_13.01.2020 55
Operation
Figure 50: FOX compression adjuster with 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 the fork to feel stiffer and you are riding on soft ground.
The lever positions between the OPEN and HARD positions provide fine adjustment of compression
damping.
We recommend setting the compression adjuster
lever to the OPEN position first.
6.11 Gear shift
The selection of the appropriate gear is a
prerequisite for a physically comfortable ride and
making sure that the electric drive system
functions properly. The ideal pedalling frequency
is between 70 and 80 revolutions per minute.
Stop pedalling briefly when changing gears. This makes it easier to switch gears and reduces wear on
the drivetrain.
1
1
2
MY20K08-2_1.0_13.01.2020 56
Operation
6.11.1 Using the derailleur gears
Only applies to bicycles with this equipment
The speed and range can be increased while
applying the same force if you select the right
gear. Use the derailleur gears.
Figure 51: Down shifter (1) and up shifter (2) on the left (I) and right (II) gear shift
Select the appropriate gear with the shifter.
The gear shift switches the gear. The shifter returns to its original position.
Clean and lubricate the rear derailleur if the gear change blocks.
6.11.2 Using the hub gear
Only applies to bicycles with this equipment
Use of the hub gear is described in Figure 52.
Turn the twist grip (1) backwards to switch up a gear (4).
Turn the twist grip (1) forwards to switch down a gear (2).
The gear shift switches the gear.
The screen display (3) shows the changed
gear.
III
1
22
1
Crash caused by incorrect use
If the rider applies too much pressure on the
pedals during a gear change and activates the
shifter or changes several gears at a time, their
feet may slip from the pedals. This may cause a
crash or flip-over with 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.
CAUTION
!
Notice
The interior hub is not completely waterproof. If
water gets into the hub, it may rust and the gear
switch function may no longer function as a result.
Never use the 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.
Never detach the hub yourself. Contact your
specialist dealer.
MY20K08-2_1.0_13.01.2020 57
Operation
Figure 52: Example: use of Shimano Nexus gear shift
1
2
3
4
MY20K08-2_1.0_13.01.2020 58
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
Servicing measures must be performed regularly.
Contact your specialist dealer if you are unsure.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits from the stanchions and deflector seals with a damp cloth.
Check the stanchions for dents, scratches, staining or leaking oil.
Check the air pressure.
Lubricate the dust seals and stanchions.
7.1.2 Cleaning the rear frame damper
Remove dirt and deposits from the damper body with a damp cloth.
Check rear frame damper for dents, scratches, staining or leaking oil.
7.1.3 Cleaning the pedals
Clean with a brush and soapy water after riding through dirt or rain.
Service the pedals after cleaning.
Clean the pedals after each ride
Clean the suspension fork and, if
necessary, rear frame damper after each ride
Chain (mainly tarmacked road) every
250–300 km
Basic cleaning and preservation of all
components
at least every six
months
Clean and lubricate the height-adjustable
seat post every six months
Check for tyre wear once a week
Check for rim wear once a week
Check tyre pressure once a week
Check brakes for wear once a month
Check electrical cables and Bowden
cables for damage and ensure they are
fully functional
once a month
Check chain tension once a month
Check tension of the spokes every three
months
Check the gear shift setting every three
months
Check suspension fork and, if necessary,
rear frame damper for wear and ensure
fully functional
every three
months
Check for wear on brake discs at least every six
months
Required tools and cleaning agents:
• Cloth
•Air pump
•Brush
• Water
• Dish-washing liquid
•Bucket
MY20K08-2_1.0_13.01.2020 59
Cleaning and servicing
7.2 Basic cleaning 7.2.1 Cleaning the frame
1Soak the entire frame with dish-washing
detergent if the dirt is thick and ingrained.
2After leaving it to soak for a short time, remove
the dirt and mud with a sponge, brush and
toothbrushes.
3Use a watering can or your hand to rinse the
frame.
4Service the frame after cleaning.
7.2.2 Cleaning the stem
1Clean stem with a cloth and soapy water.
2Service the stem after cleaning.
7.2.3 Cleaning the wheel
1Check the tyres, rims, spokes and spoke
nipples for any damage when cleaning the
wheel.
2Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
3Clean the rim with a sponge.
7.2.4 Cleaning the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
4Service the drive elements after cleaning.
7.2.5 Cleaning the rear frame damper
Clean rear frame damper with a cloth and soapy water.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairs.
This may cause a crash with injuries.
Never apply care products or oil to the brake
discs or brake linings, or the braking surfaces
on the rims.
After cleaning, servicing or repair, carry out a
few test brake applications.
Notice
Water may enter the inside of the bearings if you
use a steam jet. This dilutes the lubricant inside,
the friction increases and, as a result, the
bearings are permanently damaged in the long
term.
Never clean the bicycle with a pressure
washer.
Greased parts, such as the seat post, the
handlebars or the stem, may no longer be safely
and reliably clamped.
Never apply grease or oil to clamping sections.
Required tools and cleaning agents:
•Cloths
• Sponge
•Air pump
•Brush
• Toothbrush
• Paintbrush
• Watering can
•Bucket
•Water
• Dish-washing liquid
• Degreaser
• Lubricant
• Brake cleaner or spirit
CAUTION
!
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
WARNING
!
MY20K08-2_1.0_13.01.2020 60
Cleaning and servicing
7.2.6 Cleaning the chain
1Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
2Dampen a cloth with soapy water. Place the
cloth on the chain.
3Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
4If the chain is still dirty afterwards, clean with
lubricant.
5Service the chain after cleaning.
Carefully clean the drive unit with a damp, soft cloth.
7.2.7 Cleaning the brake
Clean brake and brake discs with a brush, water and dish-washing detergent.
Clean brake discs thoroughly with brake cleaner or spirit.
7.3 Servicing 7.3.1 Servicing the frame
Dry the frame.
Spray with care oil.
Clean off the care oil again after a short time.
Notice
Never use aggressive (acid-based) cleaners,
rust removers or degreasers when cleaning
the chain.
Never use chain cleaning devices or chain
cleaning baths.
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 pressure
washer or compressed air.
Take great care when using a hosepipe. Never
point the water jet directly at the seal section.
WARNING
!
Required tools and cleaning agents:
•Cloths
• Toothbrushes
• Dish-washing liquid
• Care oil for frames
• Silicone or Teflon oil
• Acid-free lubricating grease
• Fork oil
• Chain oil
• Degreaser
• Spray oil
• Teflon spray
MY20K08-2_1.0_13.01.2020 61
Cleaning and servicing
7.3.2 Servicing the stem
Apply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point.
If you have speedlifter Twist, also apply oil to the unlocking bolt using the groove in the speedlifter body.
Apply a little acid-free lubricant grease between the stem quick release lever and the sliding piece to
reduce the quick release lever operating force.
7.3.3 Servicing the fork
Treat the dust seals with fork oil.
7.3.4 Servicing the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
7.3.5 Servicing the pedals
Treat pedals with spray oil.
7.3.6 Servicing the chain
Grease the chain thoroughly with chain oil.
7.3.7 Servicing the drive elements
Service front and rear derailleur articulated shafts and jockey wheels with Teflon spray.
7.4 Maintenance
The following maintenance measures must be
performed on a regular basis.
7.4.1 Wheel
1Check the tyres for wear.
2Check the tyre pressure.
3Check the rims for wear.
The rims of a rim brake with invisible wear
indicator are worn as soon as the wear
indicator becomes visible in the area of the rim
joint.
The rims with visible wear indicator are worn as
soon as the black, all-round groove on the pad
friction surface is no longer visible. We
recommend that you also replace the rims with
every second brake lining replacement.
4Check the tension of the spokes.
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
Notice
If the tyre pressure is too low in the tyre, the tyre
does not achieve its load bearing capacity. The
tyre is not stable and may come off the rim.
If the tyre pressure is too high, the tyre may burst.
Check the tyre pressure as per specifications
Adjust the tyre pressure as necessary.
WARNING
!
MY20K08-2_1.0_13.01.2020 62
Cleaning and servicing
7.4.1.1 Checking the tyres
Check the tyre wear. The tyre is worn if the anti-puncture protection or the carcass cords are visible.
A specialist dealer will need to change the tyre
if it is worn.
7.4.1.2 Checking the rims
Check the rims for wear. The rims are worn as soon as the black, all-round groove on the pad friction
surface becomes invisible.
Contact your specialist dealer to have the rims
replaced. We recommend that you also replace
the rims at the same time as every second
brake lining replacement.
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve
Only applies to bicycles with this equipment
The tyre pressure cannot be measured on the
simple Dunlop valve. The tyre pressure is
therefore measured in the filling hose when
pumping slowly with the bicycle pump.
It is recommendable to use a bicycle pump with a
pressure gauge. The operating instructions for the
bicycle pump must be adhered to.
1Unscrew and remove the valve cap.
2Connect the bicycle pump.
3Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
4Adjust the tyre pressure according to
specifications in the bicycle pass.
5If the tyre pressure is too high, unfasten the
union nut, let air out and re-tighten the union
nut.
6Remove the bicycle pump.
7Screw the valve cap tight.
8Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.4 Checking and adjusting the tyre
pressure – presta valve
Only applies to bicycles with this equipment
It is recommendable to use a bicycle pump with a
pressure gauge. The operating instructions for
the bicycle pump must be adhered to.
1Unscrew and remove the valve cap.
2Open the knurled nut around four turns.
3Carefully apply the bicycle pump so that the
valve insert is not bent.
4Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
5Correct the tyre pressure as per the
specifications on the tyre.
6Remove the bicycle pump.
7Tighten the knurled nut with your fingers.
8Screw the valve cap tight.
9Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve
Only applies to bicycles with this equipment
It is recommendable to use a bicycle pump with a
pressure gauge. The operating instructions for
the bicycle pump must be adhered to.
1Unscrew and remove the valve cap.
2Attach the bicycle pump.
3Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
MY20K08-2_1.0_13.01.2020 63
Cleaning and servicing
4Remove the bicycle pump.
5Screw the valve cap tight.
6Screw the rim nut (1) gently against the rim
with the tips of your fingers.
7.4.2 Brake system
The maintenance interval for the brake depends
on the weather conditions and how frequent the
bicycle is used. If the bicycle is used under
extreme conditions such as rain, dirt or high
mileage, maintenance must be performed more
frequently.
7.4.3 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
1Check that the brake linings are no less than
1.8 mm wide at any point and no less than
2.5 mm between the brake lining and
supporting plate.
2Push brake lever and hold. In doing so, check
the transport safety wear gauge can fit
between the brake lining supporting plates.
The brake linings have not reached their wear
limit. Contact your specialist dealer if any of
these components are worn.
7.4.4 Checking the pressure point
Push brake lever and hold several times.
If you are unable to clearly detect the pressure
point and it changes, the brake needs to be
vented. Contact your specialist dealer.
7.4.5 Checking the brake discs for wear
Check that the brake disc is no less than 1.8 mm at any point.
The brake discs have not reached their wear
limit yet; brake discs need to be replaced if
they have. Contact your specialist dealer.
7.4.6 Electrical cables and brake cables
Check all visible electrical cables and cables for damage. If the sheathing is compressed, a brake is
defective or a light does not work, the bicycle must be removed from service until the lines or cables
have been repaired. Contact your specialist dealer.
7.4.7 Gear shift
Check the gear shift and the shifter or the twist grip setting and adjust it as necessary.
7.4.8 Stem
The stem and quick release system must be inspected at regular intervals. The specialist dealer should
adjust them if necessary.
If the hexagon socket head screw is also loosened, the headset backlash also needs to be adjusted.
Medium-strength thread locker, such as Loctite blue, then needs to be applied to the loosened screws
and the screws tightened as per specifications.
Contact your specialist dealer if there is any wear or signs of corrosion.
Crash caused by brake failure
Worn brake discs and brake linings, as well as a
lack of hydraulic fluid in the brake cable, reduce
the braking power. This may cause a crash with
injuries.
Check the brake disc, brake linings and
hydraulic brake system on a regular basis.
Contact your specialist dealer if any of these
components are worn.
CAUTION
!
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Cleaning and servicing
7.4.9 Checking the belt and chain tension
1Check the chain tension in three or four
positions, turning the crank a full revolution.
Figure 53: Checking the chain tension
Notice
Excessive chain tension increases wear.
If the chain tension is too low, there is a risk that
the chain or the drive belt will slip off the chain
wheels.
Check the chain tension once a month.
2 cm
MY20K08-2_1.0_13.01.2020 65
Cleaning and servicing
2If the chain can be pushed more than 2 cm, the
chain or drive belt will need to be tensioned
again by the specialist dealer.
3If the chain or the drive belt can only be pushed
up and down less than 1 cm, you will need to
slacken the chain or the drive belt.
The optimum chain tension is achieved if the
chain or the drive belt can be pushed a
maximum of 2 cm in the middle between the
pinion and the toothed wheel. The crank must
also turn without resistance.
4If a hub gear is featured, the rear wheel must
be pushed backwards or forwards to tighten
the chain. Contact your specialist dealer.
5Check the handlebar grip is firmly in position.
MY20K08-2_1.0_13.01.2020 66
Maintenance
8 Maintenance
You must have the specialist dealer perform
maintenance every six months as a minimum.
This is the only way to ensure that bicycles remain
safe and fully functional. No matter whether disc
brakes need replacing, brakes venting or wheels
changing, many maintenance tasks require
technical expertise, special tools and special
lubricants. The bicycle may become damaged if
the stipulated maintenance intervals and
procedures are not carried out. That is why only
specialist dealers may carry out maintenance.
The retailer will check the bicycle based on the
maintenance table in the Section 10.2.
The specialist dealer will inspect the bicycle for
any signs of material fatigue during basic
cleaning.
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 on air forks, overhaul the air suspension,
change the oil and replace the dust wipers.
They will pay particular attention to rim and
brake wear. The spokes are re-tightened in
accordance with the findings.
Injury due to damaged brakes
Special tools and specialist knowledge are
required to repair the brakes. Incorrect or
unauthorised assembly can damage the brakes.
This may lead to an accident with injuries.
Only specialist dealers may carry out repairs
on brakes.
Only carry out work or changes, such as
dismantling, sanding or painting, which are
permitted and described in the brake operating
instructions.
Injury to the eyes
Problems may arise if the settings are not made
properly and you may sustain serious injuries as
a result.
Always wear safety glasses to protect your
eyes when carrying out maintenance work
such as replacing components.
Crash caused by material fatigue
If the service life of a component has expired, the
component may suddenly fail. This may cause a
crash with injuries.
Have the specialist dealer carry out six-
monthly basic cleaning of the bicycle,
preferably at the same time as the required
servicing work.
WARNING
!
CAUTION
!
Hazard for the environment due to toxic
substances
The brake system contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
CAUTION
!
MY20K08-2_1.0_13.01.2020 67
Maintenance
8.1 Axle with quick release
8.1.1 Checking the quick release
Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 54: Adjusting the quick release clamping force
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Afterwards, check the quick release lever
position and clamping force.
Figure 55: Adjusting the quick release clamping force
Crash caused by unfastened quick
release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Install the front wheel quick release lever on
the opposite side to the brake disc.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
CAUTION
!
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the frame may break. This will
cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
MY20K08-2_1.0_13.01.2020 68
Maintenance
8.2 Adjusting the gear shift
If you cannot select the gears effortlessly, you will
need to adjust the setting for the shift cable
tension.
Carefully pull the adjusting sleeve away from
the shifter housing, turning it as you do so.
Check the gear shift function after each
adjustment.
8.2.1 Cable-operated gear shift,
single-cable
Only applies to bicycles with this equipment
For a smooth gear shift, adjust the adjusting
sleeves on the shifter housing.
Figure 56: Adjusting sleeve (1) for the single-cable, cable-operated gear shift with shifter housing (2), example
8.2.2 Cable-operated gear shift,
dual-cable
Only applies to bicycles with this equipment
For a smooth gear shift, set the adjusting
sleeves underneath the chain stay on the
frame.
The shift cable has around 1 mm play when it
is pulled out gently.
Figure 57: Adjusting sleeves (2) on two alternative versions (A and B) of a dual-cable, cable-operated gear shift on the chain
stay (1)
2
1
1
A
B
1
2
2
1
MY20K08-2_1.0_13.01.2020 69
Maintenance
8.2.3 Cable-operated twist grip,
dual-cable
Only applies to bicycles with this equipment
For a smooth gear shift, set the adjusting
sleeves on the shifter housing.
There is noticeable play of around 2–5 mm
(1/2 gear) when twisting the twist grip.
Figure 58: Twist grip with adjusting sleeves (1) and play of the gear shift (2)
2
MY20K08-2_1.0_13.01.2020 70
Troubleshooting, fault clearance and repair
9 Troubleshooting, fault clearance
and repair
9.1 Repair
Special knowledge and tools are required for
many repairs. That is why only a specialist dealer
may perform repairs such as:
• Replacing tyres and rims
• Replacing brake pads and brake linings
• Replacing and tensioning the chain.
9.1.1 Original parts and lubricants
The individual parts of bicycles have been
selected carefully and match to one another.
Only original parts and lubricants must be used for
maintenance and repair.
The constantly updated accessory approval and
parts list are Section 11, Documents and
Drawings.
Observe the operating instructions for the new
components.
9.1.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.1.3 Adjusting the headlight
The headlight must be positioned, so that its
light beam meets the road 10 m in front of the
bicycle.
9.1.4 Tyre clearance check
The tyre needs to be checked each time a
suspension fork tyre is changed to another size.
1Release pressure from the fork.
2Press fork together fully.
3Measure the gap between the top of the tyre
and the crown’s lower surface. The gap must
not be less than 10 mm. If the tyre is too large,
the tyre will touch the crown’s lower surface if
the fork is fully pressed together.
4Release pressure on fork and pump it up again
if it is an air suspension fork.
5Take into account the fact that the gap will be
smaller if there is a guard. Check again to
ensure that there is sufficient clearance for the
tyre.
MY20K08-2_1.0_13.01.2020 71
Recycling and disposal
10 Recycling and disposal
The bicycle is recyclable material. You must
dispose of it and recycle it separately from the
domestic waste in compliance with applicable
statutory regulations. Separate collection and
recycling saves raw materials and ensures that all
the regulations for protection of health and the
environment are met when recycling the product.
Never dismantle the bicycle for disposal purposes.
You can return the bicycle 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 and free from frost, where they
are protected from direct sunlight.
MY20K08-2_1.0_13.01.2020 72
Documents
10.1 Assembly report
Date: Frame number:
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance Rejection
Front wheel Assembly O.K. Loose Adjust quick release
Kickstand Check mount fastening Functional check O.K. Loose Retighten screws
Tyres Tyre pressure check O.K. Tyre pressure too low/too
high Adjust tyre pressure
Frame Check for damage –
fracture, scratches O.K. Damage detected Take out of operation, new frame
Handles, coverings Check mount fastening O.K. Not provided Retighten screws, new handles or
coverings as specified in parts list
Handlebars, stem Check mount fastening O.K. Loose Retighten screws; new stem as
specified in parts list if necessary
Steering headset Check for damage Functional check O.K. Loose Retighten screws
Saddle Check mount fastening O.K. Loose Retighten screws
Seat post Check mount fastening O.K. Loose Retighten screws
Protective plate Check mount fastening O.K. Loose Retighten screws
Pannier rack Check mount fastening O.K. Loose Retighten screws
Attachments Check mount fastening O.K. Loose Retighten screws
Bell Functional check O.K. No ring, too quiet, missing New bell as specified in the parts
list
Suspension elements
Fork, suspension
fork Check for damage O.K. Damage detected New fork as specified in the parts
list
Rear frame damper Check for damage O.K. Damage detected New fork as specified in the parts
list
Suspension seat post Check for damage O.K. Damage detected New fork as specified in the parts
list
Brake system
Brake lever Check mount fastening O.K. Loose Retighten screws
Brake fluid Check fluid level O.K. Too little Refill with brake fluid; new brake
hoses if damaged
Brake linings
Check brake linings,
brake discs or rims for
damage
O.K. Damage detected New brake linings, brake discs or
rims
Back-pedal brake
braking armature Check mount fastening O.K. Loose Retighten screws
Light system
Dynamo/battery First examination O.K. Fault Taking out of service, new
battery or dynamo
Light cabling Connections, correct
wiring O.K. Cable defective, no light New cabling
Rear light Side light Functional check O.K. No constant light
Take out of service; new rear
light as specified in parts list;
replace if necessary
Front light Side light, daytime riding
light Functional check O.K. No constant light
Take out of service; new front
light as specified in parts list;
replace if necessary
Reflectors All complete, state,
fastening O.K. Damaged or not all
complete
New reflectors
Drive/gear shift
Chain/cassette/
pinion/chainring Check for damage O.K. Damage Refasten if necessary or replace
as specified in parts list
MY20K08-2_1.0_13.01.2020 73
Documents
Technical check, test ride
Chain guard/spoke
guard Check for damage O.K. Damage Replace as specified in parts list
Bottom bracket axle/
crank Check mount fastening O.K. Loose Retighten screws
Pedals Check mount fastening O.K. Loose Retighten screws
Shifter Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables Check for damage Functional check O.K. Loose or defective Adjust shift cables; new shift
cables if necessary
Front derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Rear derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Components Description Criteria Measures if rejected
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long
Locate defective part in brake
system and correct
Gear shift under
operating load
Functional check O.K. Problems when shifting
gear
Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
Functional check O.K. Suspension too deep or no
longer exists
Locate defective component and
correct
Light system Functional check O.K. No continuous light, too
bright
Locate defective part in light
system and correct
Test ride No strange
noises
Strange noises Locate source of noise and
correct
Date
Fitter's name:
Final inspection by workshop manager
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Documents
10.2 Maintenance instructions
Diagnosis and documentation of current status
Date: Frame number:
Components Frequency Description Criteria Measures if rejected
Inspection Tests Maintenance Accept-
ance
Rejection
Front wheel 6 months Assembly O.K. Loose Adjust quick release
Kickstand 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Tyres 6 months Tyre pressure check O.K. Tyre pressure
too low/too high Adjust tyre pressure
Frame 6 months Check for damage –
fracture, scratches O.K. Damage
detected
Take bicycle out of service,
new frame
Handles, cover-
ings 6 months Wear; check if fas-
tened securely O.K. Not provided
Retighten screws, new hand-
les or coverings as specified
in parts list
Handlebars,
stem 6 months Check mount fastening O.K. Loose
Retighten screws; new stem
as specified in parts list if
necessary
Steering head-
set 6 months Check for damage Functional check Lubricating and adjust-
ment O.K. Loose Retighten screws
Saddle 6 months Check mount fastening O.K. Loose Retighten screws
Seat post 6 months Check mount fastening O.K. Loose Retighten screws
Protective plate 6 months Check mount fastening O.K. Loose Retighten screws
Pannier rack 6 months Check mount fastening O.K. Loose Retighten screws
Attachments 6 months Check mount fastening O.K. Loose Retighten screws
Bell 6 months Functional check O.K. No ring, too
quiet, missing
New bell as specified in the
parts list
Suspension elements
Fork, suspen-
sion fork
To manu-
facturer`s
specificati-
ons
Check for damage –
corrosion, fracture
Maintenance as speci-
fied by manufacturer
Lubrication, oil change
as specified by manu-
facturer
O.K. Damage
detected
New fork as specified in the
parts list
Rear frame
damper
To manu-
facturer`s
specificati-
ons
Check for damage –
corrosion, fracture
Maintenance as speci-
fied by manufacturer
Lubrication, oil change
as specified by manu-
facturer
O.K. Damage
detected
New fork as specified in the
parts list
Suspension
seat post
To manu-
facturer`s
specificati-
ons
Check for damage Maintenance as speci-
fied by manufacturer O.K. Damage
detected
New fork as specified in the
parts list
Brake system
Brake lever 6 months Check mount fastening O.K. Loose Retighten screws
Brake fluid 6 months Check fluid level Depending on time of
year O.K. Too little
Top up brake fluid; take
bicycle out the out of ser-
vice if damaged; new brake
hoses
Brake linings 6 months
Check brake linings,
brake discs or rims for
damage
O.K. Damage
detected
New brake linings, brake
discs or rims
Back-pedal
brake braking
armature
6 months Check mount fastening O.K. Loose Retighten screws
Brake system 6 months Check mount fastening Functional check O.K. Loose Retighten screws
MY20K08-2_1.0_13.01.2020 75
Documents
Technical inspection, checking safety, test ride
Inspection Tests Maintenance Accept-
ance
Rejection
Light system
Dynamo 6 months
First examination O.K. Error message Contact battery manufactu-
rer; take out of service, new
battery
Light cabling 6 months Connections, correct
wiring
O.K. Cable defective,
no light
New cabling
Rear light 6 months
Side light Functional check O.K. No constant light New rear light as specified in
parts list; replace if neces-
sary
Front light 6 months
Side light, daytime
riding light
Functional check O.K. No constant light New front light as specified
in parts list; replace if neces-
sary
Reflectors 6 months All complete, state,
fastening
O.K. Damaged or not
all complete
New reflectors
Drive/gear shift
Chain/cassette/
pinion/chain-
ring
6 months
Check for damage O.K. Damage Refasten if necessary or
replace as specified in parts
list
Chain guard/
spoke guard 6 months Check for damage O.K. Damage Replace as specified in parts
list
Bottom bracket
axle/crank 6 months Check mount fastening O.K. Loose Retighten screws
Pedals 6 months Check mount fastening O.K. Loose Retighten screws
Shifter 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables 6 months Check for damage Functional check O.K. Loose or defec-
tive
Adjust shift cables; new shift
cables if necessary
Front derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible
Adjust
Rear derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible
Adjust
Components Frequency Description Criteria Measures if rejected
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long
Locate defective part in brake system and correct
Gear shift under
operating load
Functional check O.K. Problems when shifting
gear
Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
Functional check O.K. Suspension too deep or no
longer exists
Locate defective component and correct
Light system Functional check O.K. No continuous light, too
bright
Locate defective part in light system and correct
Test ride No strange
noises
Strange noises Locate source of noise and correct
Date
Fitter's name:
Final inspection by workshop
manager
MY20K08-2_1.0_13.01.2020 76
Glossary
11 Glossary
Bicycle for young adults
Source: ISO 4210-2: bicycle designed for use on
public roads by a young adult whose weight is less
than 40 kg, with maximum saddle height of
635 mm or more and less than 750 mm (see
ISO 4210).
Brake lever
Source: EN 15194:2017: lever used to apply the
brake.
Braking distance
Source: EN 15194:2017: distance that a bicycle
travels from when braking commences until the
bicycle reaches the point where it comes to rest.
Cargo bike
Source: DIN 79010: bicycle mainly designed to
carry goods.
CE marking
Source: Directive on Machinery: the manufacturer
uses the CE marking to declare that the bicycle
complies with the applicable requirements.
City and trekking bicycles
Source: ISO 4210-2: bicycle designed for use on
public roads primarily for means of transportation
or leisure.
Consumables
Source: EN 82079-1: any part or material that is
needed to continue using or maintain the product.
Decommissioning
Source: DIN 31051: intentional, unlimited
interruption in an object's functional capability.
Disc brake
Source: EN 15194:2017: brake in which brake
pads are used to grip the lateral faces of a thin
disc attached to or incorporated into the wheel
hub.
Drive belt
Source: EN 15194:2017: seamless ring belt which
is used as a means of transmitting drive force.
Electrical control system
Source: EN 15194:2017: electronic and/or
electrical component or an assembly of
components provided for installation into a
vehicle, together with all electrical connections
and associated wiring for the motor electrical
power assistance.
Electrically power assisted cycle, bicycle
Source: EN 15194:2017: electrically power
assisted cycle, equipped with pedals and an
auxiliary electric motor, which cannot be propelled
exclusively by means of the auxiliary electric
motor, except in start-up assistance mode.
Emergency stop
Source: ISO 13850:2015, Function or signal,
designed: — to avert arising or reduce existing
hazards to persons, damage to machinery or to
work in progress; – to be initiated by a single
human action.
Fault
Source: EN 13306:2018-02, 6.1: state of an item
(4.2.1) characterized by its inability to perform a
required function (4.5.1), excluding such inability
during preventive maintenance or other
scheduled actions or due to lack of external
resources.
Folding bicycle
Source: ISO 4210-2: bicycle designed to fold into
a compact form, facilitating transport and storage.
Fork steerer
Source: EN 15194:2017: part of a fork that rotates
around the steering axis of a bicycle frame head
tube. It is normally connected to the fork crown or
directly to the fork legs, and is normally the point
of connection between the fork and the handlebar
stem.
MY20K08-2_1.0_13.01.2020 77
Glossary
Fracture
Source: EN 15194:2017: unintentional separation
into two or more parts.
Maintenance
Source: DIN 31051: maintenance is generally
performed at regular intervals and often carried
out by trained technical staff. This ensures a
maximum service life and low wear and tear for
the maintained items. Proper maintenance is
often also a pre-requisite for providing a warranty.
Maximum continuous power
Source: ZEG: the maximum continuous power is
the maximum power for the electric motor output
shaft during 30 minutes.
Maximum saddle height
Source: EN 15194:2017: vertical distance from
the ground to the point where the top of the seat
surface is intersected by the seat-post axis,
measured with the saddle in a horizontal position
and with the seat-post set to the minimum
insertion-depth mark.
Maximum tyre pressure
Source: EN 15194:2017: maximum tyre pressure
recommended by the tyre or rim manufacturer for
a safe and efficient performance. If the rim and
tyre both indicate a maximum tyre pressure, the
maximum inflation pressure is the lower of the two
pressures indicated.
Minimum insertion depth mark
Source: EN 15194:2017: mark indicating the
minimum insertion depth of handlebar stem into
fork steerer (fork stem) or seat post into frame.
Model year
Source: ZEG: the model year refers to the first
production year that the series-manufactured
bicycle was manufactured in the version in
question and is not always identical to the year of
manufacture. The year of manufacture may be
before the model year in some cases. If no
technical modifications are made to the series,
bicycles from a previous model year may also be
produced after the model year in question.
Mountain bike
Source: ISO 4210-2: bicycle designed for use off-
road on rough terrain, on public roads, and on
public pathways, equipped with a suitably
strengthened frame and other components, and,
typically, with wide-section tyres with coarse tread
patterns and a wide range of transmission gears.
Negative deflection
Negative deflection or sag is fork compression
caused by the weight of the rider and their gear
(e.g. a backpack), their sitting position and the
frame geometry.
Off-road rough terrain
Source: EN 15194:2017: rough gravel tracks,
forest trails and other generally off-road tracks
where tree roots and rocks are likely to be
encountered.
Operating instructions
Source: ISO/DIS 20607:2018: part of the user
information that machine manufacturers provide
to machine operators; it contains guidance,
instructions and tips related to the use of the
machine in all its life cycle phases.
Permitted total weight
Source: EN 15194:2017: weight of the fully
assembled bicycle plus the rider and baggage, as
specified by the manufacturer.
Pressure point
Source: ZEG: The pressure point on a brake is the
point on the brake lever where the brake disc or
brake pads respond and the braking process is
initiated.
Quick-release device, quick release
Source: EN 15194:2017: lever actuated
mechanism that connects, retains or secures a
wheel or any other component.
MY20K08-2_1.0_13.01.2020 78
Glossary
Racing bicycle
Source: ISO 4210-2: bicycle designed for amateur
rides at high speed and for use on public roads
having a control and steering assembly with
multiple grip positions to provide an aerodynamic
posture, a multi-speed transmission system and a
tyre width not greater than 28 mm with the fully
assembled bicycle having a maximum mass of
12 kg.
Rebound
The rebound defines the speed at which the fork
rebounds after being loaded.
Rechargeable battery
Source: DIN 40729:1985-05: a rechargeable
battery is an energy storage device that can store
supplied electrical energy as chemical energy
(charging) and release it as electrical energy
when required (discharging).
Seat post
Source: EN 15194:2017: component that clamps
the saddle (with a bolt or assembly) and connects
it with the frame.
Serial number
Source: ZEG: each bicycle has an eight-digit type
number which is used to specify the design model
year, the type and the version.
Shut-off speed
Source: EN 15194:2017: speed reached by the
bicycle at the moment the current has dropped to
zero or to the no load current value.
Slippage
Source: DIN 75204-1:1992-05: the difference in
relation to vehicle speed between the vehicle
speed and the speed of its wheels at their
circumference.
Spare part
Source: EN 13306:2018-02, 3.5: item intended to
replace a corresponding item in order to retain or
maintain the original required function of the item.
Suspension fork
Source: EN 15194:2017: front wheel fork
incorporating controlled, axial flexibility to reduce
the transmission of road-shocks to the rider.
Suspension frame
Source: EN 15194:2017: frame incorporating
controlled, vertical flexibility to reduce the
transmission of road-shocks to the rider.
Total deflection
Source: Benny Wilbers, Werner Koch: Neue
Fahrwerkstechnik im Detail (New chassis
technology in detail): The distance that the wheel
travels between an unloaded and a loaded
position is called total deflection. When at rest, the
vehicle’s mass is applied to the springs and
reduces the total deflection by the negative
deflection to the positive deflection.
Wear
Source: DIN 31051: reduction in useful life (4.3.4),
caused by chemical and/or physical processes.
Weight of ready-to-ride bicycle
Source: ZEG: the indicated weight for a ready-to-
ride bicycle refers to the weight of a bicycle at the
time of sale. The weight of each additional
accessory must be added to this weight.
Wheel
Source: EN 15194:2017: assembly or
combination of hub, rim and spokes or disc, but
excluding tyre assembly.
Work environment
Source: ISO 9000:2015: set of conditions under
which work is performed.
Year of manufacture
Source: ZEG: the year of manufacture is the year
when the bicycle was manufactured. The
production period is always from August to July of
the following year.
MY20K08-2_1.0_13.01.2020 79
Keyword index
12 Keyword index
A
Air valve,
Fork, 10
B
Back-pedal brake,
-braking, 53
Battery,
- disposing of, 71
Belt tension, 64
Brake arm, 11
Brake calliper, 11
Brake disc, 11
Brake lever, 18
- adjusting the pressure point, 42
Brake lining, 11
- maintaining, 63
C
Chain guard,
- checking, 49
Chain tension, 64
Chain, 7
- maintaining, 64
Charger,
- disposing of, 71
Clamping force,
- Checking the quick releases, 23
- Setting the quick releases, 23
Control panel 18
D
Display 18
F
Fork, 8
Fork end, 8
Frame, 7
Front wheel brake, 11, 12
- braking, 53
Front wheel, see Wheel
G
Gear shift twist grip,
- checking, 63
Gear shift,
- maintaining, 63
- switching, 55
H
Handlebars, 7, 18
Headlight, 18
Hub, 8
I
Initial commissioning, 20
M
Minimum insertion depth marking, 34
Mudguards,
- checking, 49
O
On-screen indicator, 48
P
Packaging, 20
Pannier rack, 7
- changing, 51
- checking, 49
- using, 50
Pedal, 12
Position, 18
Q
Quick release, 8
R
Rear frame damper,
structure, 10
Rear wheel brake, 11, 12
Riding light,
- checking function, 49
Rim brake locking lever 11
Rim, 8
- checking, 61
Roller brake,
-braking, 53
S
Saddle, 7
- changing the saddle tilt, 32
- changing the seat length, 36
- determining the saddle height, 32,
36
Seat post, 7
Shifter,
- checking, 63
- setting, 68
Spoke, 8
Stem,
- checking,
Handlebars,
- checking, 29
Suspension head, 8
T
Transportation, 19
Transporting, see Transportation
Tyres, 8
- checking, 61
U
Using 56
V
Valve, 8
Dunlop valve, 8
Presta valve, 8
Schrader valve, 8
W
Wheel,
- installing, 21, 22, 23, 26, 27, 28, 29
- maintaining, 61
… 64 …

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