Bulls Alpine Hawk EVO, Grinder EVO Carbon, Millennial EVO Carbon, Grinder EVO, WildFlow EVO RS Operating Instructions Manual

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TRANSLATION OF THE ORIGINAL

OPERATING INSTRUCTIONS

19-22-1001, 19-22-1002, 19-22-1003, 19-17-1033, 19-22-4001, 19-17-4003, 19-18-1061, 19-18-1062

034-03275 • 1.0 • 23 November 2018

Alpine Hawk EVO, Grinder EVO, Grinder EVO Carbon,

Harrier EVO, Millennial EVO, Millennial EVO Carbon,

WildFlow EVO RS, WildFlow EVO SL

E-BIKES

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Distribution or reproduction of these operating instructions and utilisation or communication of their content is prohibited unless expressly approved. Any infringement will render the offender liable for compensation. All rights reserved in the event that a patent, utility model or industrial design is registered.

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Data sheet

Surname, first name of the purchaser:

Date of purchase:

Model:

Frame number:

Type number:

Unladen weight (kg):

Tyre size:

Recommended tyre pressure (bar)*: front: rear:

Wheel circumference (mm):

Company stamp and signature:

*After a tyre change, refer to the tyre markings for the permitted tyre pressures and make sure that they are observed. The recommended tyre pressure must not be exceeded.

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Table of contents

1 About these instructions 8

1.1 Manufacturer 8

1.2 Laws, standards and directives 9

1.3 Other valid documents 9

1.4 Subject to change 10

1.5 Language 10

1.6 For your safety 11

1.6.1 Instruction, training and customer service 11

1.6.2 Basic safety notes 12

1.6.3 Warnings 12

1.6.4 Safety markings 13

1.7 For your information 13

1.7.1 Instructions for actions 13

1.7.2 Information on the type plate 13

1.7.3 Language conventions 16

1.8 Type plate 17

1.9 Identifying 18

1.9.1 Operating instructions 18

1.9.2 Bicycle 18

2 Safety 19

2.1 Requirements for the rider 19

2.2 Hazards for vulnerable groups 19

2.3 Personal protective equipment 19

2.4 Proper use 19

2.4.1 City and trekking bicycle 20

2.4.2 Mountain bike 20

2.4.3 Racing bicycle 21

2.4.4 Improper use 22

2.4.5 City and trekking bicycle 22

2.4.6 Mountain bike 23

2.4.7 Racing bicycle 23

2.5 Duty of care 24

2.5.1 Operator 24

2.5.2 Rider 24

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Table of contents

3 Description 25

3.1 Overview 25

3.2 Handlebars 26

3.3 Wheel and fork 27

3.3.1 Valve 27

3.3.2 Suspension 29

3.3.3 Suspension fork structure 30

3.3.3.1 Rear frame damper structure 31

3.4 Brake system 32

3.4.1 Rim brake 32

3.4.2 Disc brake 34

3.4.3 Back-pedal brake 35

3.5 Electric drive system 36

3.5.1 Drive unit 38

3.5.2 Rechargeable battery 39

3.5.3 Control panel 41

3.5.3.1 Display bar 42

3.5.3.2 Level of assistance 43

3.6 Charger 44

4 Technical data 45

5 Transportation, storage and assembly 49

5.1 Transportation 49

5.1.1 Transporting the battery 51

5.1.2 Using the transport securing system 51

5.2 Storing 52

5.2.1 Break in operation 53

5.2.1.1 Preparing a break in operation 53

5.2.1.2 Taking out of operation 53

5.3 Assembly 54

5.3.1 Required tools 54

5.3.2 Unpacking 55

5.3.3 Scope of delivery 55

5.3.4 Commissioning 56

5.3.4.1 Checking the battery 58

5.3.5 Mounting the wheel in the Suntour fork 59

5.3.5.1 Mounting the wheel with screw-on axle (15 mm) 59

5.3.5.2 Mounting the wheel with screw-on axle (20 mm) 61

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Table of contents

5.3.5.3 Mounting the wheel with a quick release axle 62

5.3.6 Mounting the wheel with a quick release 66

5.3.7 Mounting the wheel in the FOX fork 69

5.3.7.1 Mounting the wheel with the quick release (15 mm) 69

5.3.7.2 Adjusting the FOX quick release 70

5.3.7.3 Mounting the wheel with Kabolt axles 72

5.3.7.4 Checking the stem and handlebars 73

5.3.8 Sale of the bicycle 74

6 Before the first ride 75

6.1 Adjusting the saddle 75

6.1.1 Adjusting the saddle tilt 75

6.1.2 Determining the seat height 76

6.1.3 Adjusting the seat height with quick release 77

6.1.4 Setting the height-adjustable seat post 79

6.1.4.1 Lowering the saddle 79

6.1.4.2 Raising the saddle 79

6.1.5 Adjusting the seat position 80

6.2 Adjusting the handlebars 81

6.2.1 Adjusting the height of the handlebars 82

6.2.2 Turning the handlebars to the side 83

6.2.2.1 Checking the clamping force of the quick releases 84

6.2.2.2 Adjusting the quick release clamping force 84

6.3 Adjusting the brake lever 85

6.3.1 Adjusting the pressure point on a Magura brake lever 85

6.3.2 Adjusting the grip distance 86

6.3.2.1 Adjusting the grip distance on a Magura brake lever 87

6.4 Adjusting the suspension of the Suntour fork 88

6.4.1 Adjusting the negative deflection 89

6.4.1.1 Adjusting the air suspension fork negative deflection 89

6.4.1.2 Adjusting the steel suspension fork negative deflection 91

6.4.2 Adjusting the rebound 92

6.5 Adjusting the suspension of the FOX fork 93

6.5.1 Adjusting the negative deflection 93

6.5.2 Adjusting the rebound 96

6.6 Adjusting the Suntour rear frame damper 97

6.6.1 Adjusting the negative deflection 97

6.6.2 Adjusting the rebound 98

6.6.3 Setting the compression 99

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Table of contents

6.7 Adjusting the FOX rear frame damper 100

6.7.1 Adjusting the negative deflection 100

6.7.2 Adjusting the rebound 102

6.8 Retracting brake linings 103

7 Operation 104

7.1 Before each ride 106

7.2 Check list before each ride 107

7.3 Charger 108

7.3.1 Connecting the charger to the mains 110

7.4 Rechargeable battery 111

7.4.1 Charging the battery 114

7.4.1.1 Charging the battery in the drive unit 116

7.4.1.2 Charging the battery on the bicycle 117

7.4.2 Inserting the battery into the drive unit 118

7.4.3 Removing the battery from the drive unit 119

7.5 Drive unit 119

7.5.1 Installing the drive unit on the bicycle 119

7.5.2 Removing the drive unit from the bicycle 121

7.6 Drive system 123

7.6.1 Switching on the drive system 123

7.6.2 Switching off the drive system 123

7.6.3 Shutting down the drive system 124

7.7 Control panel 125

7.7.1 Using the push assist system 125

7.7.2 Selecting the level of assistance 126

7.8 Gear shift 127

7.8.1 Using the derailleur gears 127

7.9 Brake 128

7.9.1 Using the brake lever 132

7.9.2 Using the back-pedal brake 132

7.10 Suspension and damping 133

7.10.1 Adjusting the compression of the Fox fork 133

7.10.2 Adjusting the compression of the Fox damper 134

8 Maintenance 136

8.1 Cleaning and servicing 138

8.1.1 After each ride 138

8.1.1.1 Cleaning the suspension fork 138

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Table of contents

8.1.1.2 Cleaning the rear frame damper 138

8.1.1.3 Cleaning the pedals 138

8.1.2 Basic cleaning 139

8.1.2.1 Cleaning the frame 140

8.1.2.2 Cleaning the stem 140

8.1.2.3 Cleaning the rear frame damper 140

8.1.2.4 Cleaning the wheel 140

8.1.2.5 Cleaning the drive elements 141

8.1.2.6 Cleaning the chain 141

8.1.2.7 Cleaning battery 142

8.1.2.8 Cleaning the display 142

8.1.2.9 Cleaning the drive unit 143

8.1.2.10 Cleaning the brake 144

8.1.3 Servicing 145

8.1.3.1 Servicing the frame 145

8.1.3.2 Servicing the stem 145

8.1.3.3 Servicing the fork 145

8.1.3.4 Servicing the drive elements 145

8.1.3.5 Servicing the pedal 145

8.1.3.6 Servicing the chain 146

8.1.3.7 Servicing the drive elements 146

8.2 Maintenance 147

8.2.1 Wheel 147

8.2.2 Brake system 148

8.2.3 Electrical cables and brake cables 148

8.2.4 Gear shift 148

8.2.5 Stem 149

8.2.6 Checking the chain and belt tension 149

8.2.7 USB port 150

8.2.8 Suspension fork 150

8.3 Service 151

8.4 Adjusting and repairing 153

8.4.1 Use original parts and lubricants only 153

8.4.2 Axle with quick release 154

8.4.2.1 Checking the quick release 155

8.4.3 Adjusting the tyre pressure 156

8.4.3.1 Dunlop valve 156

8.4.3.2 Presta valve 157

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Table of contents

8.4.3.3 Schrader valve 158

8.4.4 Adjusting the gear shift 159

8.4.5 Cable-operated gear shift, single-cable 159

8.4.6 Cable-operated gear shift, dual-cable 160

8.4.7 Cable-operated twist grip, dual-cable 161

8.4.8 Offsetting the brake lining wear 162

8.4.9 Hydraulically operated rim brake 162

8.4.10 Hydraulically operated disc brake 163

8.4.11 Replacing the lighting 163

8.4.12 Setting the headlight 163

8.4.13 Repair by the specialist dealer 163

8.4.14 Repair by the specialist dealer 164

8.4.15 First aid 165

8.4.16 Drive system or control panel does not start up 167

8.5 Accessories 168

8.5.1 Child seat 168

8.5.2 Bicycle trailer 170

8.5.3 Pannier rack 171

9 Recycling and disposal 172

9.1 EC declaration of conformity 174

9.2 Table of figures 175

9.3 List of tables 178

9.4 Index 179

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About these instructions

1 About these instructions

Read these operating instructions before commissioning the bicycle to ensure you use all the functions correctly and safely. The operating instructions are not a substitute for personal instruction by the supplying specialist dealer. The operating instructions are a component part of the bicycle. Therefore, if it is re-sold at a later time, they must be handed over to the subsequent owner.

These operating instructions are mainly intended for the rider and operator of the bicycle, who tend to be non-professionals

Text passages which are expressly intended for specialist staff (e.g. bicycle mechanics) are clearly marked with a tool symbol.

Staff at all specialist dealers have specialist training and qualifications, and are therefore capable of identifying risks and preventing hazards which may arise during maintenance, servicing and repairs on the bicycle. Information for specialist staff does not require non-professionals to take any action.

1.1 Manufacturer

The manufacturer of the bicycle is:

ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Straße 2 50739 Köln, Germany

Tel.: +49 221 17959 0 Fax: +49 221 17959 31 E-mail: info@zeg.de Internet: www.zeg.de

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About these instructions

1.2 Laws, standards and directives

These operating instructions comply with the essential requirements from:

• Machinery Directive 2006/42/EC,

• Electromagnetic Compatibility Directive 2014/30/EU,

• EN ISO 12100:2010 Safety of machinery – General principles of design – Risk assessment and reduction,

• EN 15194:2015, Cycles – Electrically power assisted cycles – EPAC bicycles,

• EN ISO 4210, Cycles – Safety requirements for bicycles,

• EN 11243:2016, Cycles – Luggage carriers for bicycles – Requirements and test methods,

• EN 82079-1:2012, Preparation of instructions for use – Structuring, content and presentation – Part 1: General principles and detailed requirements and

• EN ISO 17100:2016-05, Translation Services – Requirements for translation service.

1.3 Other valid documents

These operating instructions are only complete in conjunction with the other valid documents.

The following document applies for this product:

• Charger operating instructions.

No other information is also applicable.

The constantly updated lists of approved accessories and parts are available to specialist dealers.

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About these instructions

1.4 Subject to change

The information contained in these operating instructions are the approved technical specifications at the time of printing. Any significant changes are included in a new issue of the operating instructions.

You will find any modifications to these operating instructions at: www.bulls.de/service/downloads

1.5 Language

The original operating instructions are written in German. A translation is not valid without the original operating instructions.

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About these instructions

1.6 For your safety

The safety concept of the bicycle comprises four elements:

• rider and/or operator instruction, and bicycle maintenance and repair by the specialist dealer,

• the chapter on general safety,

• the warnings in these instructions and

• the safety marking on the type plates.

1.6.1 Instruction, training and customer service

The supplying specialist dealer will provide customer service. Contact details can be found on the back page of these operating instructions and in the data sheet. If you are unable to contact this person, you will find other specialist dealers at www zeg.de.

The specialist dealer authorised to perform repairs and maintenance work receives regular training.

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The rider or the operator of the bicycle will be instructed in person on the bicycle functions when the supplying specialist dealer hands over the bicycle, if not before. This instruction particularly covers the bicycle's electrical functions and correct use of the charger.

Each rider to whom this bicycle is provided must receive instruction on the bicycle's functions. The operating instructions must be submitted to each rider in printed form and must be acknowledged and adhered to.

SIGNAL WORD

DANGER

WARNING

CAUTION

NOTICE

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About these instructions

1.6.2 Basic safety notes

These operating instructions have a chapter with general safety notes [ distinguish this chapter as it has a grey background.

 Chapter 2, page 19]. You can

1.6.3 Warnings

Hazardous situations and actions are marked with warnings. The warnings in these operating instructions are shown as follows:

Type and source of the danger

Description of the danger and the consequences.



Measures

The following pictograms and signal words are used in the operating instructions for warnings and information notices:

Will lead to serious or even fatal injuries if ignored. High-risk hazard.

May lead to serious or even fatal injuries if ignored. Medium-risk hazard.

May lead to minor or moderate injuries. Low-risk hazard.

May lead to material damage if ignored.

Table 1: Meanings of the signal words

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About these instructions

1.6.4 Safety markings

The following safety markings are used on the bicycle's type plates:

General warning

Adhere to the instructions for use

Table 2: Meaning of safety markings

1.7 For your information

1.7.1 Instructions for actions

Instructions for actions are structured in accordance with the following pattern:

 Requirements (optional)



Instruction for action

 Result of the action (optional)

1.7.2 Information on the type plate

Alongside the warnings, the type plates of the products also contain other important information on the bicycle:

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About these instructions

Suitable for tarmacked and paved roads – no off-road riding or jumps

Suitable for tarmacked roads, cycle paths and firm gravel paths and roads, longer sections with moderate slopes and jumps up to 15 cm.

Suitable for tarmacked roads, cycle paths and easy to demanding off-road riding, sections with moderate slopes and jumps up to 61 cm.

Suitable for tarmacked roads, cycle paths and easy to demanding off-road riding, limited downhill use up to 25 km and jumps up to 122 cm.

Suitable for tarmacked roads, cycle paths and easy to extremely difficult off-road riding, unlimited downhill use and any jumps

Table 3: Relevance of area of use

City and trekking bicycle

Child's bicycle / bicycle for young adults

Mountain bike

Racing bicycle

Carrier bicycle

Folding bicycle

Table 4: Relevance of bicycle type

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max. 50°C

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About these instructions

Read the instructions

Separate collection of electrical and electronic devices

Separate collection of ordinary and rechargeable batteries

Must not be thrown into fire (burning prohibited)

It is forbidden to open any type of battery

Device of protection class II

Only suitable for use indoors

Fuse (device fuse)

EU conformity

Recyclable material

Protect from temperatures above 50 °C and direct sunlight

Table 5: Relevance of safety instructions

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About these instructions

1.7.3 Language conventions

The bicycle described in these operating instructions may be equipped with alternative components. The equipment of the bicycle is defined by the respective type number. Where applicable, the word Alternative beneath the heading indicates alternatively used components. The following terms are used for better legibility:

Term Meaning

Operating instructions

Bicycle Electric motor driven cycle Motor Drive motor

The following conventions are used in these operating instructions:

Original operating instructions or translation of the original operating instructions

Convention Use

Italics Entry in the index SPACED Indicators on the display

screen

[

 Example, page

Cross references

numbering]

• Bulleted lists

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ZEG Zweirad-Einkaufs-

Genossenschaft eG

Longericher Str. 2

50739 Köln, Germany

Typ:

19-16-0001

EN 15194

0,25 kW / 25 km/h

zGG 180 kg EPAC 25 kg

BJ 2018 / MJ 2019

nach

EPAC

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About these instructions

1.8 Type plate

The type plate is situated on the frame. The type plate features the following information:

Figure 1: Type plate, example

1 CE marking 2 Manufacturer 3 Type number 4 Nominal continuous power 5 Permitted total weight

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6 Year of manufacture 7 Bicycle type 8 Safety instructions 9 Disposal instruction 10 Area of use 11 Model year 12 Weight of the ready-to-ride bicycle 13 Shut-off speed

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About these instructions

1.9 Identifying

1.9.1 Operating instructions

The identification number of these operating instructions is made up of the document number, the version number and the release date. It can be found on the cover page and in the footer.

Identification number 034-03275_1.0_23.11.2018

Table 6: Identification number of the operating instructions

1.9.2 Bicycle

These BULLS operating instructions refer to the model year 2019. The production period is from August 2018

to July 2019. They are issued in August 2018.

The operating instructions are a component part of the following bicycles:

Type number

19-22-1001 Harrier EVO Racing bicycle

19-22-1002 Grinder EVO Racing bicycle

19-22-1003 Grinder EVO Carbon Racing bicycle

19-17-1033 Millennial EVO City and trekking bicycle

19-22-4001 Alpine Hawk EVO Racing bicycle

19-17-4003 Millennial EVO Carbon City and trekking bicycle

19-18-1061 WildFlow EVO RS Mountain bike

19-18-1062 WildFlow EVO SL Mountain bike

Model Bicycle type

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! ! !

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2 Safety

2.1 Requirements for the rider

The physical and mental abilities of the rider must be sufficient for riding on public roads.

2.2 Hazards for vulnerable groups

Legal guardians hold sole responsibility for determining whether minors are capable of using the bicycle.

2.3 Personal protective equipment

We recommend that you wear a suitable safety helmet. We also recommend that you wear typical, long, close-fitting cycling clothing and sturdy footwear.

Safety

2.4 Proper use

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The bicycle may only be used in a perfect, fully functional condition. National requirements may apply to the bicycle which differ from the standard equipment. For riding on public roads, some special regulations apply in relation to the driving light, reflectors and other components.

The general laws and the regulations for the prevention of accidents and environmental protection in the respective country of use must be adhered to. Proper use also includes all instructions for actions and check lists in these operating instructions. Approved accessories can be installed by specialist staff. The drive system is only intended for use during a bicycle journey and must not be used for other purposes.

Each bicycle is categorised [ bicycle type, which determines its designated use.

 Table 4, page 14] as a

! !

! ! !

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Safety

2.4.1 City and trekking bicycle

City and trekking bicycles are designed for daily, comfortable use. They are suitable for riding on public roads.

Area of use

Suitable for tarmacked and paved roads.

Suitable for tarmacked roads, cycle paths and firm gravel paths and roads, and longer sections with

2.4.2 Mountain bike

moderate slopes and jumps up to 15 cm.

The mountain bike is designed for sporting use. The design characteristics include a short wheelbase, a sitting position with the rider inclined towards the front, and a brake requiring low actuation force.

A mountain bike is a piece of sporting equipment. It requires an adaptation period as well as physical fitness. Use requires the appropriate training; in particular riding in bends and braking should be practised.

The strain on the rider, in particular the hands and wrists, arms, shoulders, neck and back, is accordingly high. Inexperienced riders tend to brake excessively and lose control as a result.

Area of use

Suitable for tarmacked roads, cycle paths and easy to demanding off-road riding, sections with moderate slopes and jumps up to 61 cm.

Suitable for tarmacked roads, cycle paths and easy to demanding off-road riding, limited downhill use and jumps up to 122 cm.

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! ! !

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Suitable for tarmacked roads, cycle paths and easy to extremely difficult off-road riding, unlimited downhill use and any jumps

2.4.3 Racing bicycle

A racing bicycle is designed for fast rides on roads and paths with a good, undamaged road surface.

A racing bicycle is a piece of sporting equipment and not a means of transport. A racing bicycle is characterised by its lightweight structure and a design which is stripped to the minimum parts required for riding.

The frame geometry and the layout of the operating elements are designed in such a way that the bicycle can be ridden at high speeds. The frame design requires practice to ensure the ride is able to ride slowly, apply the brakes and get on and off the bike safely.

The sitting position is athletic. The strain on the rider, in particular the hands and wrists, arms, shoulders, neck and back, is accordingly high. The sitting position therefore requires physical fitness.

Safety

Area of use

Suitable for tarmacked and paved roads.

Suitable for tarmacked roads, cycle paths and firm gravel paths and roads, and longer sections with moderate slopes and jumps up to 15 cm.

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! !

! ! !

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Safety

2.4.4 Improper use

Failure to adhere to the proper use poses a risk of personal injury and material damage. The bicycle is not suitable for the following uses:

• riding with a damaged or incomplete bicycle

• riding over steps

• riding through deep water

• lending the bicycle to untrained riders

• carrying other people

• riding with excessive luggage

• riding with no hands

2.4.5 City and trekking bicycle

• 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 are not sports bicycles. If used for sports, the rider can expect reduced riding stability and diminished comfort.

Forbidden areas of use

Never drive off-road or perform jumps.

Never drive off-road or perform jumps over 15 cm.

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! ! !

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2.4.6 Mountain bike

A mountain bike must be retrofitted with lighting, a guard etc. according to the applicable national laws and regulations before it can be used in public street traffic.

Safety

Forbidden areas of use

Never ride downhill or perform jumps over 61 cm.

Never traverse extremely difficult off-road terrain or

2.4.7 Racing bicycle

perform jumps over 122 cm.

Never exceed your personal limits.

Racing bikes must be retrofitted with lighting, a guard and other fittings as specified by national laws and regulations before they are used on public roads.

Forbidden areas of use

Never drive off-road or perform jumps.

Never drive off-road or perform jumps over 15 cm.

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! !

! ! !

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Safety

2.5 Duty of care

The safety of the bicycle can only be assured if all the necessary measures are taken.

2.5.1 Operator

The operator has the duty of care and responsibility for scheduling these measures and checking that they are implemented.

The operator:

2.5.2 Rider

• makes these operating instructions available to the rider for the duration of use of the bicycle. If necessary, they translate the operating instructions into a language which the rider understands.

• familiarises the rider with the functions of the bicycle before the first ride. Only riders who have received instruction may be allowed to ride.

• instructs the rider on proper use and the wearing of personal protective equipment.

• only employs specialist staff for maintenance and repair of the bicycle.

The rider:

• receives instruction before the first ride. They can clarify any questions relating to the operating instructions with the operator or specialist dealer

• wears personal protective equipment.

• assumes all the obligations of the operator in case the bicycle changes hands.

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910

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Description

3 Description

3.1 Overview

Figure 2: Bicycle viewed from the right, Alpine Hawk EVO used as example

1 Front wheel 2 Fork 3 Handlebars 4 Stem 5 Frame 6 Seat post 7 Saddle 8 Rear wheel 9Chain 10 Rechargeable battery, frame number and type

plate

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Description

3.2 Handlebars

Figure 3: Detailed view of bicycle from rider position, example

1 Rear brake lever 2 Front brake lever 3 Control panel 4 Fork lock on suspension fork head 5 Shifter

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3.3 Wheel and fork

Figure 4: Components of the wheel – example showing front wheel

1 Tyre 2Rim 3 Suspension fork head with setting wheel 4Fork 5 Spoke 6 Quick release 7Hub 8 Valve 9 Fork end of the suspension fork

Description

3.3.1 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.

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Description

Dunlop valve

The rider can easily exchange the valve and quickly release the air. The air pressure cannot be measured with this valve.

Presta valve

The Presta valve requires a smaller hole in the rim, which is why it is especially suitable for the narrow rims of racing bicycles. The air pressure can be measured with this valve.

Schrader valve

The rider can fill the Schrader valve very easily at a petrol station. The air pressure can be measured with this valve.

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3.3.2 Suspension

Both forks and suspension forks are fitted in this model series. A suspension fork is based either on a steel spring or air suspension. Unlike a rigid fork, a suspension fork has two functions which improve floor contact and comfort: suspension and damping.

Description

Figure 5: Bicycle without suspension (1) and with suspension (2) when

riding over an obstacle

The suspension prevents an impact, such as one caused by a stone lying in the bike's path, from being channelled directly into the rider's body via the fork. The impact is absorbed by the suspension system instead. This causes the suspension fork to compress. The compression can be disabled so that a suspension fork reacts like a rigid fork. The switch to disable the fork is called a remote lockout.

After compressing, the suspension fork returns to its original position. If there is a damper, it decelerates movement, preventing the suspension system from springing back in an uncontrolled manner and stopping the fork from vibrating up and down.

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Description

Dampers which dampen compressive deflection movements, i.e. a compression load, are called compression dampers or compression dashpots.

Dampers which dampen rebound deflection movements, i.e. a rebound load, are called rebound dampers or dashpots.

3.3.3 Suspension fork structure

Figure 6: Example showing FOX fork

The stem and handlebars are fastened to the fork shaft (3). The wheel is fastened to the quick release axle (7). Other elements: Stanchion (1) and spring setting wheel (2), compression setting (4), crown (5), dust

seal (6) and quick release lever (7)

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25-30%

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3.3.3.1 Rear frame damper structure

The rear frame damper features air suspension, a compression damper and a rebound damper.

Figure 7: Example showing FOX rear frame damper

Description

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1 Guide rod eye 2Air valve 3 Setting wheel 4 Lever 5 Air chamber 6O-ring

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Description

3.4 Brake system

The bicycle's brake system comprises either a hydraulic:

• rim brake on the front and rear wheels,

• disc brake on the front and rear wheels or

• a rim brake on the front and rear wheels and an additional back-pedal brake.

3.4.1 Rim brake

Alternative

Figure 8: Rim brake components with details; Magura HS22 used as an

example

1 Rear wheel rim brake 2 Brake booster 3 Brake lining 4 Handlebars with brake levers 5 Front wheel rim brake

The rim brake stops the wheel moving when the rider pulls the brake lever, causing two brake linings, positioned opposite one another, to be pressed onto the rims.

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The hydraulic rim brake features a locking lever

Figure 9: Rim brake locking lever, closed (1) and open (2)

The rim brake locking lever is not marked with any lettering. Only a specialist dealer may set the rim brake locking lever.

Description

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Description

3.4.2 Disc brake

Alternative

Figure 10: Bicycle brake system with a disc brake, example

1Brake disc 2 Brake calliper with brake linings 3 Handlebars with brake levers 4 Front wheel brake disc 5 Rear wheel brake disc

On a bicycle with a disc brake, the brake disc is screwed permanently to the hub of the wheel.

The brake lever is pulled to increase brake pressure. The brake fluid is used to transfer pressure through the brake lines to the cylinders in the brake calliper. The braking force is boosted by a speed reduction and applied to the brake linings. These apply the brake disc mechanically. If the brake lever is pulled, the brake linings are pressed against the brake disc, and the movement of the wheel is decelerated until it comes to a stop.

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3.4.3 Back-pedal brake

Alternative

Figure 11: Brake system with a back-pedal brake, example

1 Rear wheel rim brake 2 Handlebars with brake levers 3 Front wheel rim brake 4 Pedal 5 Back-pedal brake

Description

The back-pedal brake stops the movement of the rear wheel when the rider pedals in the opposite direction to the direction of travel.

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Description

3.5 Electric drive system

The bicycle is driven by muscle power via the chain drive. The force which is applied by pedalling in the direction of travel, drives the front chain wheel. The chain transmits the force onto the rear chain wheel and then onto the rear wheel.

Figure 12: Diagram of mechanical drive system

1 Direction of travel 2 Chain 3 Rear chain wheel 4 Front chain wheel 5 Pedal

The bicycle also has an integrated, electric drive system.

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The electric drive system is made up of 5 components:

Figure 13: Diagram of electric drive system

1 Control panel 2 Bottom-bracket gears 3 Drive unit 4 Rechargeable battery 5 A charger which is designed for the battery.

Description

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Description

3.5.1 Drive unit

Figure 14: Drive unit

As soon as the required muscle power from the rider pedalling passes a certain level, the motor is activated gently and assists the pedalling motion of the rider. The motor force is determined by the set level of assistance. The system performance is determined using the pedal assistance settings on the control panel.

The bicycle does not have a separate emergency stop or emergency shut-off button. The motor switches off automatically as soon as the rider no longer pedals, the temperature is outside the permitted range, there is an overload or the shut-off speed of 25 km/h has been reached.

When you step on the pedals again and the speed drops below 25 km/h, the system starts again

A push assist system can be activated. The speed depends on the selected gear. The rider brakes the bicycle by holding the bicycle while pushing.

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3.5.2 Rechargeable battery

Figure 15: Rechargeable battery, view of charging port side

1 Charging port 2 On-Off button 3 Charge status indicator (battery)

Description

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The lithium ion battery has an internal electronic protection circuit. This is matched to the charger and bicycle motor. The battery temperature is monitored at all times. The battery is protected against deep discharge, overcharging, overheating and short circuit. In the event of a hazard, a protective circuit switches the battery off automatically. If the bicycle has not been moved for 10 hours and no button has been pressed on the control panel or the charge status of the battery falls below 30%, the bicycle has not been moved for 3 hours and no button has been pressed on the control panel, the electric drive system and the battery automatically switch off to save energy.

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Description

The battery's service life can be extended if it is well maintained and, above all, stored at the correct temperatures. The battery charge status will decrease with age, even if the battery is maintained properly. If the operating time is severely shortened after charging, this is a sign that battery has reached the end of its useful life.

Transportation temperature 5°C–25°C

Ideal transportation temperature 10 °C–15 °C

Storage temperature 5°C–25°C

Ideal storage temperature 10 °C–15 °C

Charging ambient temperature 10 °C–30 °C

Table 7: Rechargeable battery technical data

When the battery is switched on, the charge status indicator shows the start animation. The LEDs then briefly indicate the charge status of the battery.

If the battery is switched on, the charge status can be queried by briefly pressing the On-Off button.

The five green LEDs on the charge status indicator show the battery charge status when the battery is switched on. Each LED represents 20% of the charge status.

When the battery is discharged, the last LED lights up intermittently. The charge status of the battery is also shown on the display.

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6 6 6 6

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3.5.3 Control panel

Figure 16: Overview of the structure and operating elements

Designation

1 Display bar

2 Top button

3 Middle button

4 Bottom button

5 Extension cable

6 Charge status indicator or pedal assistance

7 Status screen

Table 8: Operating element overview

Description

The control panel controls the drive system via three buttons and displays either the charge status of the battery or the pedal assistance selected.

The bicycle's battery supplies the control panel with energy when a sufficiently charged battery is inserted into the bicycle, and the drive system is switched on.

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Description

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Protection rating (with USB cover closed)

Weight about 0.075 kg

Table 9: Display technical data

3.5.3.1 Display bar

The control panel display bar consists of 11 LEDs. The uppermost LED serves as a status display to provide information on the status of your e-bike. The remaining 10 LEDs serve as an indicator for the charge status and pedal assistance.

Status screen

The status screen indicates a status change or an existing fault. The status indicator does not light up if no fault is detected.

The different colours of the status screen have the following meaning:

Colour Meaning

The status screen briefly flashes green after the

green

Yellow

Red

Table 10: Meaning of status screen colours

drive pack has been successfully installed in the bicycle. This gives you a visual signal that the system can now be switched on.

The status screen briefly turns yellow when a "soft fault" is detected. This means that there is a temporary or non-critical disturbance, which in most cases leads to a loss of performance. In the event of a "soft fault", you can still ride your bicycle. However, this is not recommended.

The status screen briefly turns red when a "hard fault" is detected. In the event of a "hard fault", the bicycle cannot be operated and must be serviced.

IP54

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3.5.3.2 Level of assistance

You can adjust the desired level of assistance using the control panel. The pedal assistance can be changed at any time.

The higher the level of assistance, the more the drive system assists the rider when pedalling. The following levels of assistance are available.

The following levels of assistance are possible:

Level of assistance Use

NONE

BREEZE

RIVER

ROCKET

Table 11: Overview of levels of assistance

Motor assistance is deactivated. The bicycle can be used as a normal bicycle.

Low but effective support for maximum range.

Reliable assistance for most usage situations.

Maximum assistance for very demanding excursions.

Description

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Level of assistance

NONE WHITE 0% 0 W

BREEZE GREEN 75% 125 W

RI V E R B L U E 150% 250 W

RO C K E T PINK 240% 400 W

Colour

Max. assistance factor

Max. output

Remaining range

Precise information about the range of your system is not possible before or during an excursion. Several factors can influence the range of the bicycle, such as level of assistance, speed, gear switching habits, tyre type and pressure, route and weather conditions, weight of rider and bicycle or the condition or age of the battery.

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Description

3.6 Charger

The lithium ion battery has an internal electronic protection circuit. It is matched to the charger. The bicycle may therefore only be charged using the charger provided.

Nominal input voltage 100 ... 240 V AC

Frequency 50 ... 60 Hz

Output voltage 42 V DC

Charging current 2 A

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Protection class IP 54

Weight about 0.6 kg

Table 12: Charger technical data

Figure 17: Charger detail

1 Mains plug 2 LED display charger 3Mains plug 4 Connecting cable 5 Power jack

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Technical data

4 Technical data

Bicycle

Transportation temperature -20 ... +60 °C

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Discharging temperature -20 ... +60 °C

Charging temperature 0 ... +45 °C

Power output/system 250 W (0.25 kW)

Shut-off speed 25 km/h

Weight of the ready-to-ride bicycle See type plate

Table 13: Bicycle technical data

Drive unit

Continuous power rating 250 W

Max. output 400 W

Torque on chain, max. 60 Nm

Nominal voltage 36 V

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Protection class IP 54

Weight about 2kg

Table 14: Drive unit technical data

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Technical data

Rechargeable battery

Type Lithium ion battery

Nominal voltage 36 V

Nominal capacity 7Ah

Power 252 Wh

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Discharging temperature -20 ... +60 °C

Charging temperature 0 ... +45 °C

Protection class IP 54

Weight, approx. 1.4 kg

Table 15: Rechargeable battery technical data

Control panel

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Protection rating (with USB cover closed)

Weight about 0.075 kg

Table 16: Display technical data

IP54

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Technical data

Bottom-bracket gears

Assistance torque, max. 60 Nm

Q factor, min. 135 (without crank

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

Protection class IP 54

Chainline 49, 52 mm

Weight about 1.3 kg

Table 17: Bottom-bracket gears technical data

Charger

Nominal input voltage 100 ... 240 V AC

Frequency 50 ... 60 Hz

Output voltage 42 V DC

Charging current 2 A

Operating temperature -20 ... +60 °C

Storage temperature -20 ... +60 °C

arm)

Protection class IP 54

Weight about 0.6 kg

Table 18: Charger technical data

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Technical data

Emissions

A-weighted emission sound pressure level < 70 dB(A)

Total vibration level for the hands and arms

Highest effective value of weighted acceleration for the entire body

Table 19: Emissions from the bicycle*

*The safety requirements as per Electromagnetic Compatibility Directive 2014/30/EU have been met. The bicycle and the charger can be used in residential areas without restriction.

Tightening torque

Axle nut tightening torque 35 Nm - 40 Nm

Handlebars clamping screw maximum tightening torque*

Table 20: Tightening torque values*

*if there is no other data on the component

<2.5m/s²

<0.5m/s²

5Nm - 7Nm

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CAUTION

NOTICE

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Transportation, storage and assembly

5 Transportation, storage and

assembly

5.1 Transportation

Crash caused by unintentional activation

There is a risk of injury if the drive system is activated unintentionally.

 Remove the battery before the bicycle is

transported.

Risk of fire and explosion due to high temperatures

Excessively high temperatures will damage the battery. Batteries may self-ignite and explode.

 Never expose batteries to sustained direct sunlight.

Oil leak if no transport securing device

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The brake securing device prevents the brakes from being applied accidentally during transport. This could cause irreparable damage to the brake system or an oil leak, which will harm the environment.

 Never pull the brake lever when the wheel has been

dismounted.

 Always use the transport securing system when

transporting dismounted wheels.

If the bicycle is lying flat, oil and grease may leak from the bicycle.

If the shipping box with a bicycle is lying flat or on one end, it does not provide the frame and the wheels with adequate protection from damage.

 Only transport the bicycle in an upright position.

NOTICE

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Transportation, storage and assembly

Bicycle rack systems which secure the bicycle standing on its head by the handlebars or frame, generate inadmissible forces on the components during transportation. This can cause the supporting parts to break.

 Never use bicycle rack systems which secure the

bicycle standing on its head by the handlebars or frame.

 Take into account the ready-to-use bicycle's weight

when transporting it.

 Remove the display and the batteries before

transporting the bicycle.

 Protect the electrical components and connections

on the bicycle from the elements with suitable protective covers.

 Remove accessories, for example drinking bottles,

before transportation of the bicycle.

 When transporting by car, you must use a suitable

bicycle rack system.

The specialist dealer will advise you on how to select a suitable rack system properly and how to use it safely.

 Transport the bicycle in a dry, clean place where it

is protected from direct sunlight.

When shipping the bicycle, we recommend that you have the bicycle partially dismantled in the proper manner and packaged by the specialist dealer.

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Transportation, storage and assembly

5.1.1 Transporting the battery

Batteries are subject to hazardous goods regulations. Undamaged batteries may be transported by private persons in road traffic. Commercial transport requires compliance with regulations concerning packaging, labelling and the transportation of hazardous goods. Open contacts must be covered and the battery securely packaged. The parcel service must be made aware of the presence of hazardous goods in the packaging.

5.1.2 Using the transport securing system

 Insert the transport securing devices between the

brake linings.

 The transport securing device is squeezed between

the two linings.

Figure 18: Fastening the transport securing device

Transportation temperature -20 ... +60 °C

Table 21: Bicycle transport temperature

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CAUTION

NOTICE

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Transportation, storage and assembly

5.2 Storing

Risk of fire and explosion due to high temperatures

Excessively high temperatures will damage batteries. Batteries may self-ignite and explode.

 Protect batteries against heat.

 Never expose batteries to sustained direct sunlight.

If the bicycle is lying flat, oil and grease may leak from the bicycle.

If the shipping box with a bicycle is lying flat or on one end, it does not provide the frame and the wheels with adequate protection from damage.

 Only store the bicycle in an upright position.

The battery discharges when not in use. Storing a discharged battery for longer periods can cause serious damage to your battery or significantly reduce its capacity.

 I f the bicyc l e features a hydrauli c seat post, f ix only

the lower seat post or the frame into a fitting stand to prevent damage to the upper seat post and the seat post lever.

 Never place a bicycle with a hydraulic seat post

upside down on the floor; otherwise you, will damage the seat post lever.

 Store the bicycle, battery and charger in a dry,

clean location.

Storage temperature -20 ... +60 °C

Table 22: Bicycle storage temperature

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NOTICE

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Transportation, storage and assembly

5.2.1 Break in operation

The battery discharges when not in use. Storing a discharged battery for longer periods can cause serious damage to your battery or significantly reduce its capacity.

The battery may become damaged if it is connected permanently to the charger.

 Never connect the battery to the charger

permanently.

If the bicycle is to be removed from service for longer than four weeks, e.g. in winter, a break in operation has to be prepared. It is recommended to store the battery and the drive unit.

5.2.1.1 Preparing a break in operation

 Remove the battery and drive unit from the bicycle.

 Charge the battery to 60% (three LEDs of the charge

status indicator light up).

 The bicycle has to be cleaned with a damp cloth and

preserved with wax spray. Never wax the friction surfaces of the brake.

 Before longer periods without use, it is

recommendable to have your specialist dealer carry out servicing and basic cleaning and apply preservative agent.

5.2.1.2 Taking out of operation

 Check the battery after 6 months. With a charge

status of 20% or less, charge the battery to 60% again.

1 month -20 to +60 °C

3 months -20 to +45 °C

1 year -20 to +25 °C

Table 23: Storage time with 60% charge

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CAUTION

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Transportation, storage and assembly

5.3 Assembly

Crushing caused by unintentional activation

There is a risk of injury if the drive system is activated unintentionally.

 Remove the battery if it is not absolutely necessary

for assembly.

 Assemble the bicycle in a clean and dry environment.

 The working environment temperature should be

between 15 °C and 25 °C.

Working environment temperature 15 °C–25 °C

Table 24: Working environment temperature

 If a fitting stand is used, it must be approved for a

maximum weight of 30 kg.

 To reduce the weight, we recommend that you always

disconnect the battery from the bicycle when using the fitting stand.

5.3.1 Required tools

The following tools are required to assemble the bicycle:

•Knife

• Hexagon socket spanner 2 (2.5 mm, 3, mm 4 mm, 5 mm, 6 mm and 8 mm)

• Torque wrench with working range between 5 and 40 Nm

• Twelve-point square socket T-25

• Ring spanner (8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm) and

• Cross, flat head and ordinary screwdriver.

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CAUTION

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Transportation, storage and assembly

5.3.2 Unpacking

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.

The packaging material consists mainly of cardboard and plastic film.

 The packaging has to be disposed of in accordance

with the regulations of the authorities.

5.3.3 Scope of delivery

The bicycle was completely assembled in the factory for test purposes and then dismantled for transportation.

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The bicycle is 95–98% pre-assembled. The scope of delivery includes:

• the pre-assembled bicycle

• the front wheel

• the pedals

• quick release (optional)

• the charger

• the operating instructions.

The battery is supplied separately from the bicycle.

CAUTION

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Transportation, storage and assembly

5.3.4 Commissioning

Fire and explosion caused by incorrect charger

Batteries which are recharged with an unsuitable charger may become damaged internally. This may result in fire or an explosion.

 Only ever use the battery with the supplied charger.

 Mark the supplied charger and these operating

instructions clearly to prevent mix-ups – with the bicycle frame number or type number, for example .

Burns from hot drive

The drive cooler can become extremely hot during use. Contact may cause burns.

 Leave the drive unit to cool before cleaning.

Since initial commissioning of the bicycle requires special tools and specialist knowledge, only trained specialist staff may perform initial commissioning.

Experience has shown that a bicycle which has not yet been sold, is spontaneously handed to consumers as soon as it appears ready to ride.

 For this reason, every bicycle must be prepared, so

that it is fully ready for use immediately after being assembled.

 Staff should work through the initial commissioning

check list to prepare the bicycle, so that it is ready to ride.

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Transportation, storage and assembly

Initial commissioning check list

Check battery.



The battery is partially charged when delivered. Fully charge the



battery to ensure full power.

Mount the wheels, quick release and pedals.



Re-adjust the quick release clamping force if necessary.



Thoroughly degrease the brake discs in disc brakes or the brake



sides and linings in rim brakes with brake cleaner or spirit.

Place handlebars, stem and saddle in the functional position



and check they are firmly in place.

Check all the components to make sure that they are firmly in place. Check all the settings and the tightening torque on the



axle nuts.

Check the entire cable harness to make sure that it is routed properly:

• You must prevent the cable harness from coming into



contact with moving parts.

• The cable routes must be smooth and free from sharp edges.

• Moving parts must not apply any pressure or tension to the cable harness.

034-03275_1.0_23.11.2018

Check the drive system, the light equipment and the brakes to



make sure that they are fully functional and effective.

Adjust the headlight.



Set the drive system has to the national language and the



appropriate system of measurement.

Check the software version of the drive system and update it as



necessary.

Take a test drive to check the brake system, gear shift and the



electric drive system.

WARNING

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Transportation, storage and assembly

5.3.4.1 Checking the battery

Fire and explosion due to defective battery

The safety electronics on damaged or faulty batteries may fail. The residual voltage can cause a short circuit. The battery may self-ignite and explode.

 Never charge a defective battery.

The battery must be checked before it is charged for the first time.

 Press the On-Off button (battery).

 If none of the LEDs on the charge status indicator

light up, the battery may be damaged.

 The battery can be charged if at least one, but not

all, of the LEDs on the charge status indicator is lit up. Fully charge the battery before initial commissioning in order to ensure that the full capacity of the battery is available.

 After initial commissioning and before every further

use, the battery is switched on using the On-Off button.

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5.3.5 Mounting the wheel in the Suntour fork

Alternative

5.3.5.1 Mounting the wheel with screw-on axle (15 mm)

Alternative

 Insert the axle completely on the drive side.

Figure 19: Fully inserting the axle

 Tighten the axle with a 5 mm hexagon socket

spanner to 8–10 Nm.

Figure 20: Tightening the axle

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 Insert the securing screw on the non-drive side.

Figure 21: Pushing the quick release lever into the axle

 Tighten the securing screw with a 5 mm hexagon

socket spanner to 5–6 Nm.

 The lever is mounted.

Figure 22: Tightening the securing screw

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5.3.5.2 Mounting the wheel with screw-on axle (20 mm)

Alternative

 Insert the axle completely on the drive side.

Figure 23: Tightening the inserted axle

 Tighten the securing clip with a 4 mm hexagon

socket spanner to 7 Nm.

Figure 24: Tightening the axle

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CAUTION

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Transportation, storage and assembly

5.3.5.3 Mounting the wheel with a quick release axle

Alternative

Crash caused by loose quick release axle

A faulty or incorrectly installed quick release axle may become caught in the brake disc and block the wheel. This will cause a crash.

 Never fit a defective quick release axle.

Crash caused by faulty or incorrectly installed quick release axle

The brake disc becomes very hot during operation. Parts of the quick release axle may become damaged as a result. The quick release axle becomes loose. This will result in a crash and injuries.

 The quick release axle and the brake disc must be

opposite one another.

Crash caused by incorrectly set quick release axle

Insufficient clamping force will cause a detrimental transmission of force. The suspension fork or the quick release axle may break. This will result in a crash and injuries.

 Never fasten a quick release axle with a tool, such

as a hammer or pliers.

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Transportation, storage and assembly

 Insert the axle into the hub on the drive side.

Clamping version II.

Figure 25: Pushing the axle into the hub

 Tighten the axle with the red handle.

Figure 26: Tightening the axle

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Transportation, storage and assembly

 Push the quick release lever into the axle.

Figure 27: Pushing the quick release lever into the axle

 Reverse the quick release lever.

 The lever is secured.

Figure 28: Securing the lever

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Transportation, storage and assembly

 Check the position and clamping force of the quick

release lever. The quick release lever must be flush with the lower housing. You must be able to see a slight impression on the palm of your hand when you close the quick release lever.

Figure 29: Perfect position for the clamping lever

 Use a 4 mm hexagon socket spanner to adjust the

clamping lever clamping force if required. Afterwards, check the quick release lever position and clamping force.

Figure 30: Adjusting the quick release clamping force

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CAUTION

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Transportation, storage and assembly

5.3.6 Mounting the wheel with a quick release

Alternative

Crash caused by unfastened quick release

A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel. This will cause a crash.

 Never fit a defective quick release.

Crash caused by faulty or incorrectly installed quick release

The brake disc becomes very hot during operation. Parts of the quick release may become damaged as a result. The quick release comes loose. This will result in a crash and injuries.

 The front wheel quick release lever and the brake

disc must be situated on opposite sides.

Crash caused by incorrectly set clamping force

Excessively high clamping force will damage the quick release and cause it to lose its function.

Insufficient clamping force will cause a detrimental transmission of force. The suspension fork or the quick release may break. This will result in a crash and injuries.

 Never fasten a quick release using a tool (e.g.

hammer or pliers).

 Only use the clamping lever with the specified set

clamping force.

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Transportation, storage and assembly

 Before mounting, ensure that the quick release

flange is extended. Open the lever completely.

Figure 31: Open and closed flange

 Push in the quick release until you hear a clicking

sound. Make sure that the flange is extended.

Figure 32: Pushing the quick release in

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Transportation, storage and assembly

 Adjust the clamping with a half-open clamping lever

until the flange reaches the fork end.

Figure 33: Adjusting the clamping

 Fully close the quick release. Check the quick

release to ensure it is firmly in place and adjust on the flange if necessary.

 The lever is secured.

Figure 34: Closing the quick release

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Transportation, storage and assembly

5.3.7 Mounting the wheel in the FOX fork

Alternative

5.3.7.1 Mounting the wheel with the quick release (15 mm)

Alternative

The procedure for installing the 15 x 100 mm and 15 x 110 mm quick releases is the same.

 Place the front wheel in the fork ends of the fork.

Push the axle through the fork end on the non-drive side and hub.

Figure 35: Pushing the quick release in

 Open the axle lever.

 Turn the axle five to six complete revolutions

clockwise into the axle nut.

 Close the quick release. The lever must be

tensioned to the point that it leaves a mark on your hand.

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1-20 mm

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Transportation, storage and assembly

 The lever must be 1 to 20 mm ahead of the fork leg

in the closed position.

Figure 36: Spacing between lever and fork leg

 If the lever is tensioned too little or too much when

closed in the recommended position (1 to 20 mm ahead of the fork), the quick release must be adjusted.

5.3.7.2 Adjusting the FOX quick release

Figure 37: Structure of quick release from rear with (1) axle nut lock, (2) axle

nut securing screw, (3) directional arrow, (4) axle setting value and (5) axle nut

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 Record the axle setting value (4) indicated by the

directional arrow (3).

 Loosen the axle nut securing screw (2) with a

2.5 mm hex key by approx. four revolutions, but do not remove the screw completely.

 Turn the quick release lever to the open position

and loosen the axle by approx. four revolutions.

 Press the axle inward from the side of the open

lever. This pushes out the axle nut securing screw so that you can turn it out of the way.

 Push the axle further forward and turn the axle nut

clockwise to increase the lever tension or anticlockwise to reduce the lever tension.

 Reinsert the axle nut lock and tighten the screw to

0.9 Nm (8 in-lb).

034-03275_1.0_23.11.2018

 Repeat the steps for installing the axle to check

proper installation and correct adjustment.

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Transportation, storage and assembly

5.3.7.3 Mounting the wheel with Kabolt axles

Alternative

The procedure for installing the 15 x 100 mm and 15 x 110 mm Kabolt axles is the same.

 Place the front wheel in the fork ends of the fork.

Push the Kabolt axle through the fork end on the non-drive side and hub.

Figure 38: Pushing the Kabolt axle in

 Tighten the Kabolt axle screw to 17 Nm (150 in-lb)

with a 6 mm hex key.

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5.3.7.4 Checking the stem and handlebars

Checking connections

 Stand in front of the bicycle to check whether the

handlebars, stem and fork shaft are firmly attached to one another. Clamp the front wheel between your legs. Grasp the handlebar grips. Try to twist the handlebars towards the front wheel.

 The stem must not move or twist.

Firm hold

 Place your entire body weight on the handlebars

with the quick release lever closed to check that the stem is firmly in place.

 The handlebars shaft must not move downwards in

the fork shaft.

034-03275_1.0_23.11.2018

 If the handlebars shaft should move in the fork

shaft, increase the quick release lever tensioning. To do so, turn the knurled nut slightly in a clockwise direction with the quick release lever open.

 Close the lever and check the stem is firmly in

position.

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Transportation, storage and assembly

Checking the headset backlash

 To check the handlebar headset backlash, close

the quick release lever on the stem. Place the fingers of one hand on the upper headset cup, pull the front wheel brake with the other hand and try to push the bicycle backwards and forwards.

 The headset cup halves must not move towards

one another while you are doing this. Note that there may be noticeable backlash due to worn-out bearing bushes or brake lining backlash in suspension forks and disc brakes.

 If there is headset backlash in the steering headset,

you must adjust it as soon as possible; otherwise, the headset will become damaged. You must make the adjustment as described in the stem manual.

5.3.8 Sale of the bicycle

 Fill out the data sheet on the first page of the

operating instructions.

 Adjust the bicycle to the rider.

 Set the stand and the shifter, and show the

purchaser the settings.

 Instruct the operator or rider how to use all the

functions of the bicycle.

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CAUTION

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Before the first ride

6 Before the first ride

Crash caused by incorrectly adjusted torques

If a screw is fastened too tightly, it may break. If a screw is not fastened enough, it may loosen. This will result in a crash and injuries.

 Always observe the indicated torques on the screw

or in the operating instructions.

Only a correctly adjusted bicycle will guarantee you the desired ride comfort and health-promoting activity. Therefore adjust the saddle, the handlebars and the suspension to your body and your preferred riding style before the first ride.

6.1 Adjusting the saddle

6.1.1 Adjusting the saddle tilt

The saddle tilt must be adjusted to the seat height, the saddle and handlebar position, and the saddle shape to ensure an optimum fit. The seating position can be optimised in this way if needed. First, readjust the saddle after finding the handlebar position you prefer.

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Before the first ride

 Place the saddle tilt in the horizontal position to

adjust the bicycle to your needs for the first time.

Figure 39: Horizontal saddle tilt

6.1.2 Determining the seat height



To determine the seat height safely, either push the bicycle near to a wall, so that you can lean on the wall to support yourself or ask another person to hold the bicycle for you.

 Climb onto the bicycle.

 Place your heel on the pedal and extend your leg,

so that the pedal is at the lowest crank rotation point.

 The rider sits straight on the saddle if the seat is at

an optimum height. If this is not the case, you can adjust the length of the seat post to your needs.

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Before the first ride

Figure 40: Optimal saddle height

6.1.3 Adjusting the seat height with quick release

 Open the quick release on the seat post to change

the seat height. To do so, pull the clamping lever away from the seat post.

Figure 41: Seat post quick release (3) with clamping lever (5) and setting

bolt (4) in the open position (1) and in the direction of the closed position (2)

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Before the first ride

 Set the seat post at the required height.

Crash caused by an excessively high seat post setting

A seat post with is set too high will cause the seat post or the frame to break. This will result in a crash and injuries.

 Do not pull the seat post out of the frame beyond

the minimum insertion depth marking.

Figure 42: Detailed view of the seat post – examples of the minimum insertion

depth marking

 To close it, push the seat post clamping lever as far

as it will go into the seat post.

 Check the clamping force of the quick releases.

034-03275_1.0_23.11.2018

ert wer

e Position zur Best

ber in einem späteren

chmals montieren.

ie den mitgelieferten Winkel mit der in

rrichtung und stecken Sie die Hülle in die

Remotehebel

Oder

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Before the first ride

6.1.4 Setting the height-adjustable seat post

 When using your seat post for the first time, you

must give it a firm push downwards to set it in motion. This is due to the natural tendency of the seal to repel oil from the seal surface. You only need to do this before the first use or after a longer period of non-use. Once you have displaced the post through its deflection, the oil spreads on the seal and the post begins to function normally.

Figure 43: The seat post activation lever can be mounted either on the left (1)

or the right (2) side of the handlebars

6.1.4.1 Lowering the saddle

6.1.4.2 Raising the saddle

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 To lower the saddle, press your hand down on the

saddle or sit on the saddle.

 Press the seat post activation lever and hold it

down.

 Release the lever once you have reached the

required height.

 Pull the seat post activation level.

 Remove any pressure on the saddle and release

the lever once you have reached the required height.

90°

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Before the first ride

6.1.5 Adjusting the seat position

The saddle can be shifted on the saddle frame. The right horizontal position ensures an optimal leverage position for legs. This prevents knee pain and painful incorrect pelvis positions. If you have displaced the saddle more than 10 mm, you then need to adjust the saddle height again since both settings affect one another.

 To adjust the seat position safely, either push the

bicycle near to a wall, so that you can lean on the wall to support yourself or ask another person to hold the bicycle for you.

 Climb onto the bicycle.

 Place the pedals into the vertical position (3 o'clock

position) with your feet.

 The rider is sitting in the optimal sitting position if

the knee cap perpendicular line runs through the pedal axle. If the perpendicular line crosses behind the pedal, bring the saddle forward. If the perpendicular line crosses in front of the pedal, bring the saddle back. Move the saddle within its permitted displacement range only (marked on the saddle stay).

Figure 44: Knee cap perpendicular line

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Before the first ride

6.2 Adjusting the handlebars

 The handlebars must only be adjusted while the

bicycle is stationary.

 Unfasten and adjust the designated screw

connections, and clamp them with the maximum tightening torque for the clamping screws of the handlebars.

Maximum tightening torque for the clamping screws of the handlebars*

*if there is no other data on the component

Table 25: Handlebars clamping screw maximum tightening torque

Adjusting the stem

Crash caused by loose stem

Incorrectly fastened screws may come loose due to impact. The stem may no longer be firmly fixed in its position as a result. This will result in a crash and injuries.

5Nm - 7Nm

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 Check the handlebars and the quick release system

are firmly in position after the first two hours of riding.

CAUTION

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Before the first ride

6.2.1 Adjusting the height of the handlebars

Crash caused by incorrectly set clamping force

Excessively high clamping force will damage the quick release and cause it to lose its function. Insufficient clamping force will cause a detrimental transmission of force. This can cause components to break. This will result in a crash and injuries.

 Never fasten a quick release using a tool (e.g.

hammer or pliers).

 Only use the clamping lever with the specified set

clamping force.

 Open the clamping lever.

 Pull the locking lever on the stem up, and

simultaneously pivot the handlebars into the desired position.

 You feel the locking lever click into place.

 Pull out the handlebars to the required height.

 Lock the quick release.

Figure 45: Open (2) and closed (1) clamping lever on the stem; by.schulz

speedlifter used as an example

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Before the first ride

6.2.2 Turning the handlebars to the side

Alternative

Crash caused by incorrectly set clamping force

Excessively high clamping force will damage the quick release and cause it to lose its function.

Insufficient clamping force will cause a detrimental transmission of force. This will result in a crash and injuries.

 Never fasten a quick release using a tool (e.g.

hammer or pliers).

 Only use the clamping lever with the specified set

clamping force.

 Open the clamping lever.

 Pull the locking lever on the stem up, and

simultaneously pivot the handlebars into the desired position.

 You feel the locking lever click into place.

 Pull out the handlebars to the required height.

 Lock the quick release.

Figure 46: Pulling locking lever upwards; by.schulz speedlifter used as an

example

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Before the first ride

6.2.2.1 Checking the clamping force of the quick releases

 Open and close the quick releases on the stem or

the seat post.

 The clamping force is sufficient if the clamping

lever can be moved easily from the open final position into the middle and has to be pressed with the fingers or base of the thumb from the middle point onwards.

6.2.2.2 Adjusting the quick release clamping force

 If the clamping lever on the handlebars cannot be

moved into its final position, screw out the knurled nut.

 Tighten the knurled nut on the seat post if the

clamping lever's clamping force is not sufficient.

If you are unable to set the clamping force, the specialist dealer will need to check the quick release.

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Before the first ride

6.3 Adjusting the brake lever

6.3.1 Adjusting the pressure point on a Magura brake

lever

Brake failure due to incorrect setting

If the pressure point is set with brakes where the brake lining and brake disc have reached their wear limit, the brakes may fail and cause an accident with injury.

 Before you set the pressure point, ensure that the

brake lining and brake disc have not reached their wear limit.

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 47: Using the twist knob (1) to adjust the pressure point

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Before the first ride

6.3.2 Adjusting the grip distance

Crash caused by incorrectly set grip distance

If brake cylinders are set incorrectly or installed wrongly, the braking power may be lost at any time. This may cause you to fall from the bicycle and injure yourself.

 Once the grip distance has been set, check the

position of the brake cylinder and adjust it as necessary.

 Never correct the brake cylinder position without

special tools. Have a specialist dealer correct it.

The brake lever grip distance can be adjusted to ensure that it can be reached more easily. Contact your specialist dealer if the brake handle is too far from the handlebars or is hard to use.

Figure 48: Brake lever grip distance

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Before the first ride

6.3.2.1 Adjusting the grip distance on a Magura brake lever

Alternative

Use a T25 TORX® wrench to turn the setting screw to adjust the grip distance.

 Turn the setting screw in the minus (‒) direction.  The brake lever moves closer to the handlebar grip.

 Turn the setting screw in the plus (+) direction.  The brake lever moves away from the handlebar

grip.

Figure 49: Using the setting screw (2) to adjust the distance from the brake

lever to the handlebar grip (1)

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CAUTION

NOTICE

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Before the first ride

6.4 Adjusting the suspension of the Suntour fork

Alternative

The following Suntour forks can be installed in this series of models:

Aion-35 Boost

NCX

NEX

XCM-ATB

XCM

XCR32

XCR34

Table 26: Overview of Suntour forks

Crash caused by incorrectly set suspension

If the suspension is adjusted incorrectly, the fork may become damaged, so that problems may occur when steering. This will result in a crash and injuries.

 Never ride the bicycle without air in the air

suspension fork.

 Never use the bicycle without adjusting the

suspension fork to the rider's weight.

 Settings on the chassis change riding performance

significantly. You need to get used to the bicycle and break it in to prevent accidents.

Air suspension fork

Steel suspension fork

Air suspension fork

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.

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Before the first ride

6.4.1 Adjusting the negative deflection

Each rider has a different weight and sitting position. "SAG" depends on the rider's position and weight and should be between 15% and 30% of the maximum fork deflection, depending on bicycle usage and preferences.

6.4.1.1 Adjusting the air suspension fork negative deflection

Alternative

 The air valve is located under a cover on the head

of the left shock absorber. Screw off the cover.

Figure 50: Screw caps in different designs

 Screw a high-pressure pump onto the valve.

 Pump the suspension fork up to the desired

pressure. Never exceed the recommended maximum air pressure. Comply with the values of the filling pressure table.

 Remove the high-pressure pump.

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Rider weight AION, NEX XCR 32, XCR 34

< 55 kg 35 - 50 psi 40 - 55 psi

55 - 65 kg 50 - 60 psi 55 - 65 psi

65 - 75 g 60 - 70 psi 65 - 75 psi

75 - 85 kg 70 - 85 psi 75 - 85 psi

85 - 95 kg 85 - 100 psi 85 - 95 psi

< 100 kg + 105 psi + 100 psi

Max. pressure 150 psi 180 psi

Table 27: Filling pressure pump of the Suntour air forks

 Measure the distance between the crown and the

dust wiper of the fork. This distance is the total deflection of the fork.

 Push a temporarily attached cable tie downward

against the dust wiper of the fork.

 Put on your usual bicycling clothing, including

luggage.

 Sit on the bicycle in your usual riding position and

support yourself (e.g. against a wall or tree).

 Get off the bicycle without allowing it to deflect.

 Measure the distance between the dust wiper and

the cable tie. This dimension is the "SAG." The "SAG" value should be between 15% (hard) and 30% (soft) of the total fork deflection.

 Increase or reduce the air pressure until you have

reached the desired "SAG."

 Once the "SAG" is correct, re-tighten the blue air

cover cap clockwise.

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Before the first ride

If you cannot achieve the desired "SAG", you may need to make an internal adjustment. For this purpose, contact your specialist dealer.

6.4.1.2 Adjusting the steel suspension fork negative deflection

Alternative

You can adjust the fork by tensioning the spring to the rider's weight and their preferred riding style. It is not the coil spring hardness which is adjusted; it is its pretensioning. This reduces the fork's negative deflection when the rider sits on the bicycle.

Figure 51: Negative deflection setting wheel on the suspension fork crown

 The setting wheel may be located under a plastic

cover on the suspension fork crown. Remove the plastic cover by pulling it off upwards.

 Turn the negative deflection setting wheel in a

clockwise direction to increase the spring pretensioning. Turn the negative deflection setting wheel in an anti-clockwise direction to reduce it.

 The ideal setting in relation to the weight of the rider

has been achieved when the shock absorber deflects 3 mm under the stationary load of the rider. Reattach the cover after the adjustment.

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Before the first ride

6.4.2 Adjusting the rebound

Alternative

The rebound defines the speed at which the fork rebounds after being loaded. The rebound setting depends on the air pressure setting. Higher "SAG" settings require lower rebound settings.

 Turn the rebound adjuster clockwise to the closed

position until it stops.

Figure 52: Suntour rebound adjuster (2) on the fork (1)

 Turn the rebound adjuster anti-clockwise.

 Adjust the rebound in such a way that the fork

rebounds quickly, but without bottoming out upward during testing. Bottoming out is where the fork rebounds too quickly and stops moving abruptly once it has reached the full rebound distance. You will hear and feel a slight knock when this occurs.

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CAUTION

NOTICE

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Before the first ride

6.5 Adjusting the suspension of the FOX fork

Alternative

Crash caused by incorrectly set suspension

If the suspension is adjusted incorrectly, the fork may become damaged, so that problems may occur when steering. This will result in a crash and injuries.

 Never ride the bicycle without air in the air

suspension fork.

 Never use the bicycle without adjusting the

suspension fork to the rider's weight.

Settings on the chassis change riding performance significantly. You need to get used to the bicycle and break it in to prevent accidents.

The adjustment shown here represents a basic setting. The rider should change the basic setting to suit the surface and his/her preferences.

 It is advisable to make a note of the basic setting.

This way, it can be used as the starting point for subsequent, optimised settings and to safeguard against unintentional changes.

6.5.1 Adjusting the negative deflection

Negative deflection (SAG) is compression of the fork caused by the weight of the rider and their gear (e.g. a backpack), the sitting position and the frame geometry. This "SAG" is not caused by riding. Each rider has a different weight and sitting position. "SAG" depends on the rider's position and weight and should be between 15% and 20% of the maximum fork deflection, depending on bicycle usage and preferences.

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 When adjusting the "SAG", ensure that each

compression adjuster is in the open position, i.e. turned clockwise until it stops.

 The pressure is to be measured at an ambient

temperature of 21 to 24 °C.

 The air valve is located under a blue cover on the

head of the left shock absorber. S c rew of f t h e cov e r anti-clockwise.

 Place a high-pressure pump on the valve.

 Pump the suspension fork up to the desired

pressure. Never exceed the recommended maximum air pressure. Comply with the values of the filling pressure table.

 Remove the high-pressure pump.

Rider weight Rhythm 34 Rhythm 36

Minimum air pressure 40 psi (2.8 bar) 40 psi (2.8 bar)

54 - 59 kg 58 psi 55 psi

59 - 64 kg 63 psi 59 psi

64 - 68 kg 68 psi 63 psi

68 - 73 kg 72 psi 67 psi

73 - 77 kg 77 psi 72 psi

77 - 82 kg 82 psi 76 psi

82 - 86 kg 86 psi 80 psi

86 - 91 kg 91 psi 85 psi

91 - 95 kg 96 psi 89 psi

95 - 100 kg 100 psi 93 psi

100 - 104 kg 105 psi 97 psi

104 - 109 kg 110 psi 102 psi

109 - 113 kg 114 psi 106 psi

Max. pressure 120 psi (8.3 bar) 120 psi (8.3 bar)

Table 28: Filling pressure table of the FOX air fork

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 Measure the distance between the crown and the

dust wiper of the fork. This distance is the "total deflection of the fork."

 Push the O-ring downward against the dust wiper of

the fork. If an O-ring is not available, attach a cable tie to the stanchion temporarily.

 Put on your usual bicycling clothing, including

luggage.

 Sit on the bicycle in your usual riding position and

support yourself (e.g. against a wall or tree).

 Get off the bicycle without allowing it to deflect.

 Measure the distance between the dust wiper and

the O-ring or cable tie. This dimension is the "SAG." The recommended "SAG" value is between 15% (hard) and 20% (soft) of the "total fork deflection."

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 Increase or reduce the air pressure until you have

reached the desired "SAG."

 Once the "SAG" is correct, re-tighten the blue air

cover cap clockwise.

If you cannot achieve the desired "SAG", you may need to make an internal adjustment. For this purpose, contact your specialist dealer.

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6.5.2 Adjusting the rebound

The rebound defines the speed at which the fork rebounds after being loaded. The rebound setting depends on the air pressure setting. Higher "SAG" settings require lower rebound settings.

 Turn the rebound adjuster clockwise to the closed

position until it stops.

Figure 53: FOX rebound adjuster (1) on the fork

 Turn the rebound adjuster anti-clockwise.

 Adjust the rebound in such a way that the fork

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6.6 Adjusting the Suntour rear frame damper

Alternative

6.6.1 Adjusting the negative deflection

If the air pressure in the rear frame damper is exceeded or undershot, the damper can be permanently damaged.

Do not exceed the maximum air pressure of 300 psi (20 bar).

Negative deflection (SAG) is compression of the rear frame damper caused by the weight of the rider and their gear (e.g. a backpack), the sitting position and the frame geometry. This "SAG" is not caused by riding. Each rider has a different weight and sitting position. "SAG" depends on the rider's position and weight and should be between 25% and 30% of the maximum rear frame damper deflection, depending on bicycle usage and preferences.

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 Set the compression adjuster to the OPEN position

so that the SAG setting is not affected.

 Remove the cap on the air valve.

 Attach a high-pressure damper pump to the valve.

 Adjust the air pressure of the damper so that it

corresponds to your weight.

 Remove the high-pressure pump.

 Measure the distance between the rubber air

chamber seal and the end of the damper. This distance is the "total damper deflection".

 Put on your usual bicycling clothing, including

luggage. Sit on the bicycle in your usual riding position and support yourself, e.g. against a wall or tree.

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 Push the O-ring downward against the rubber air

chamber seal.

 Get off the bicycle without allowing it to deflect.

 Measure the distance between the rubber air

chamber seal and the O-ring. This dimension is the "SAG." The recommended "SAG" value is between 15% (hard) and 25% (soft) of the "total damper deflection."

 Increase or reduce the air pressure until you have

reached the desired "SAG."

6.6.2 Adjusting the rebound

The rebound defines the speed at which the rear frame damper rebounds after being loaded. The rebound setting depends on the air pressure setting. Higher "SAG" settings require lower rebound settings.

Figure 54: Suntour rebound adjuster wheel (1) on the rear frame damper

 Turn the rebound adjuster wheel in the

– direction to increase rebounding.

 Turn the rebound adjuster wheel in the

+ direction to reduce compressive deflection movements.

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