Maxon MX25, MX25B, MXUrban User Manual

USER MANUAL

Edition 2018-03

Document ID rel7971

Contents

Contents

1Operation 3

1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.2 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.3 Functional Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4 Driving Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.5 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.5.1 PowerGrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.5.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.5.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.6 Before the Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.7 Riding the Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.7.1 Power Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.7.2 Motor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.7.3 Battery Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.8 After the Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2Maintenance 13

2.1 Care & Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1.1 After each Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1.2 Storage of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.3 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.4 Replacing the rear Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.5 Cleaning the PowerGrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.1.6 Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3Technical Data 35

WARNING!

RIDING AN ELECTRIC BIKE IS DANGEROUS!

ALWAYS USE EXTREME CAUTION WHEN USING THIS PRODUCT. MISUSE
OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY OR DEATH. ONLY
USE THIS PRODUCT IF YOU ARE IN GOOD PHYSICAL HEALTH. NEVER ACT

IN A CARELESS MANNER WHEN USING THIS PRODUCT. YOU ARE

RESPONSIBLE FOR YOUR SAFETY AND THE SAFETY OF OTHERS AROUND

YOU WHEN USING THIS PRODUCT!

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SYMBOLS USED

Indicates a potentially hazardous situation. Ignoring can cause serious
injury!

Indicates a possibly dangerous situation or draws attention to an unsafe
practice. Ignoring can cause injury or damage to components!

Indicates an important aspect. Ignoring can cause damage to components!

In illustrations, only the “eye” will be displayed.

Indicates an important aspect or gives important additional information.

Operation

Components

1OPERATION

1.1 Components

Figure 1 maxon BIKEDRIVE — Components

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Operation
Legal Regulations

1.2 Legal Regulations

Legal regulations

Inquire about the current legal requirements in your country or in your area before
putting your bike into operation.

Equipped with the BIKEDRIVE, the bike is a vehicle with motorized assistance.
Depending on the country, the vehicle is called E-Bike, Pedelec (Pedal Electric
Cycle), electric or motor-assisted bicycle, electro moped, autocycle, or similar,
and is subject to appropriate legal regulations.

Federal, State, and in some cases, city laws regulate aspects, such as, traffic
rules, permitted speed, type approval and homologation, license plate, prove of
roadworthiness/road suitability before an official body, compulsory insurance,
driving license, required equipment (for example, lighting, acoustic warning
device, and specific brakes), etc.

1.3 Functional Principle

From a
standing
start in
action!

1.4 Driving Modes

Zero Motorized assistance is deactivated. You may switch to «Zero» at any time and

Power1
Power2
Power3

Boost While pedaling in the highest support level «Power3», you can continue turning

Pushing aid If you activate «Boost» without pedaling, the motor will support you while push-

Motorized assistance of the BIKEDRIVE commences as soon as you start pedal­ing while having selected a support level. The motor develops torque according
to the selected support level and the driven speed.

You can switch off and re-activate the motorized assistance at any time. With­out pedaling, you can use the motor as pushing aid.

continue “normal cycling”. Thereby, the BIKEDRIVE behaves as if completely
switched off. It runs in internal freewheel and you will not even notice that it is
there.

You will be motor-assisted while pedaling. The torque applied by the drive will
be determined by the support level you have selected with the PowerGrip and
the driven speed.

the PowerGrip to get extra short-term performance and torque.

ing the bike.

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1.5 Handling

Operation

Handling

A Word on
Safety

Selecting the
driving mode

The BIKEDRIVE is extremely powerful! It possesses an extraordinarily high
degree of dynamics that will most likely surprise you at the beginning and it will
require some time to get used to.

Take it easy to start with and use caution on your first rides!

WARNING

Risk of injury
The BIKEDRIVE it extremely powerful and highly dynamic. Lack of habituation
to the high performance, handling, or operation can lead to serious injury!

• Be aware that the BIKEDRIVE will fundamentally change the driving behavior
of your bike — particularly in respect to aspects, such as, weight, weight distri­bution, center of gravity, braking distance, braking response!

• Use extra caution during the “acclimatization phase” and select a low degree
of motorized assistance!

• Be aware that a changed setting at the PowerGrip will have an immediate
effect on the drive system, on speed, and on handling!

1.5.1 PowerGrip

By rotating the PowerGrip you select the driving mode and, thereby, the degree
of motorized assistance (“Driving Mode” on page 7). You select the level using
four snap-in and one non-latching positions.

Each change of the selected support level is temporarily displayed by LEDs 1…5.
Following a support level change and while riding, the LEDs will show the
remaining battery level (“Charging Level” on page 8). The system status is
continuously displayed with LED A (“Status Indicator” on page 8).

Figure 2 PowerGrip

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Operation
Handling

1.5.2 Battery

On the battery you will find the main switch, a lock, and displays for battery
charge and battery system status (page 8).

Figure 3 Battery BX360 ONE / BX500 ONE (left side)

Figure 4 Battery BX360 ONE / BX500 ONE (right side)

Power up To power up the battery, press the main switch. During startup, all LEDs light

up. After successful initialization, the LEDs will go out for a moment. Subse­quently, the charging level of the battery will be temporarily displayed before
the LED display will go off.

To display the battery charge level at anytime during your ride, press the main
switch.

Turn off To turn off the battery, press the main switch until the LED display goes off. This

takes about 3 seconds. This takes about 3 seconds.

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Operation

Handling

1.5.3 Displays

The PowerGrip features an LED display that will inform you about the currently
selected driving mode, the charging level of the battery, and the status of the
system. A second LED display for the charging level is located at the battery.

Dimming To prevent glare, the brightness of the PowerGrip’s LED display will automati-

cally adapt to the ambient light.

Identification of the PowerGrip

During initialization of the system, the type of PowerGrip is displayed via the
LEDs.

Identification

dotX25 dotX33 dotXUrban

Zero

Power1

Power2

Power3

Boost

Driving Mode

The selected support level is briefly displayed with each change. Thereafter, the
battery charge level is indicated.

Neutral position — motorized assistance is turned off.

The PowerGrip engages in this position.

Turning towards you from the neutral position «Zero»
switches consecutively into levels «Power1», «Power2»,
and «Power3».

Turning away from you switches consecutively one level
back.

The PowerGrip engages in the selected position.

Turning towards you from the level «Power3» switches
to level «Boost».

The PowerGrip does not engage in this position and
bounces back to level «Power3» when released.

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Operation
Before the Ride

Charging
level

Operating
condition

Charging Level

The remaining relative capacity of the battery is displayed in 20% steps.

100…80% 80…60% 60…40% 40…20% 20…0%

Status Indicator

The operating condition and system temperature (in color graduation) is dis­played.

The meaning, for example, is lights up in blue, flashes in red.

System

off

System

error

Master

halted

System
temperature

cold normal heated warm

1.6 Before the Ride

IMPORTANT—Power-up procedure

During power-up procedure, the BIKEDRIVE will perform a self test and initialization.
Moving the bike contrary to the driving direction during this process can lead to mal­function. Therefore, while power-up procedure is in process,…

• do not rotate the rear wheel backwards (contrary to the driving direction),

• do not block the rear wheel,

• do not apply brakes!

1) Make sure that the battery is sufficiently charged for your planned
tour.

2) Make sure that the battery is turned off (page 6).

3) Slide battery into battery rail, let it click into place, and lock it. Remove
key.

“Riding the Bike” on
page 9

4) Turn PowerGrip in neutral position «Zero».

5) Turn on main switch on battery.

6) After successful initialization you are good to go. Bear in mind the

safety notes on page 5!

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1.7 Riding the Bike

1.7.1 Power Limitation

In order to achieve a largest possible range, the motor power will be limited in
certain support levels (Table 1).

Operation

Riding the Bike

PowerGrip

dotX25

dotX33

dotXUrban

Table 1 Power Limitation

1.7.2 Motor Power

Support
Level

Power1 10 80

Power2 20 180

Power3 30 —

Boost 50 —

Power1 10 180

Power2 20 —

Power3 30 —

Boost 50 —

Power1 7.5 180

Power2 15 —

Power3 22.5 —

Boost 39 —

Torque

[Nm]

Limitation

[W]

While riding, various system parameters are continuously monitored. As the
motor or battery temperature reaches a certain limit, the system automatically
limits the maximum output torque. You may of course continue cycling but you
must make do with reduced motorized assistance. The actual system tempera­ture will be displayed via the PowerGrip’s multicolor LED A (“Status Indicator”
on page 8).

System
heated

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Cause: This is no reason for concern! You are using the BIKEDRIVE for what it
is made for; motorized propulsion while pedaling.
What happens now? Just keep on going!
Depending on driving behavior, topography or usage of «Boost», heating of
motor or battery will possibly further increase and will, eventually, lead to the
status indication «System warm».

Operation
Riding the Bike

System warm

Cause: You have pushed the BIKEDRIVE to the maximal permitted
temperature of the motor or the battery.
What happens now? Just keep on going!
The motor will automatically regulate to the highest possible torque output
without exceeding the maximum permitted temperature of the motor or the
battery.
The more you relieve the motor, the sooner you can expect «Boost» and to
return to reach full torque. Thereby, cooling of the battery takes significantly
longer than the cooling of the motor.

1.7.3 Battery Capacity

Among other factors, the operating range per battery charge also depends on
the following influencing factors.

How to get
the most out
of a battery
charge

Running
empty

Shutdown The BIKEDRIVE switches off completely after approximately 15 minutes without

• Gross weight and rolling friction: For example, additionally carried
weight, trailer, low tire pressure, grazing brakes, worn components,
headwind.

• Topography

• Ambient temperature: By principle, the battery can only deliver its
maximum capacity within given temperature limits (Table 6 on
page 38).

• Support level/start-up/acceleration/changing gears: The more you
make use of motorized assistance (thus especially at start-up, during
acceleration, and when climbing a hill), the less your distance and
operating range will be.
Use the gears as with a “normal” bike. Thereby, shift early into a lower
gear when climbing a hill.

You may fully discharge the battery. The internal controller ensures that the
battery does not suffer damage. However, the battery should be recharged
soon thereafter, but no later than within two weeks.

power output. To recommence the motorized ride, restart the BIKEDRIVE
(“Before the Ride” on page 8).

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1.8 After the Ride

Operation

After the Ride

If you take a
break:

After the fun
is before the
fun!

Prepare for
transport:

Always turn the BIKEDRIVE completely off whenever you are not sitting on the
bike.

1) Turn the PowerGrip in neutral position «Zero».

2) Turn the BIKEDRIVE off.

Perform the following steps for your BIKEDRIVE to deliver riding pleasure for
many years:

1) Turn the PowerGrip in neutral position «Zero».

2) Turn the BIKEDRIVE off.

3) Clean the bike (page 13).

4) Remove the battery.

5) Remove moisture from motor, PowerGrip, battery, battery rail, and
cables, if any.

6) Charge the battery (page 13)

7) Observe the instructions on battery storage (page 15).

1) Remove the battery and cover the battery rail to protect it from dirt
and humidity.

2) Protect the bike from dirt, dust, rain, snow, salt water, spray water. If
necessary, use transport bag or cover with tarpaulin.

3) Observe the bike manufacturer’s instructions if you intend to remove
the front and/or rear wheel for transport.

4) Observe the following remark on air transportation if you intend to
take your bike along on a flight.

Transport by Air

According to the International Air Transport Association (IATA), lithium batteries with
a capacity exceeding 100 Wh are considered as hazardous goods subject to appro­priate conditions for air transport. Carriage on board passenger aircraft is not per­mitted.

Note that all BIKEDRIVE batteries have a capacity of more than 100 Wh.
Check with your airline or your travel agent on means of transportation before
scheduling a flight.

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Operation
After the Ride

••page intentionally left blank••

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2MAINTENANCE

The BIKEDRIVE is designed for a demanding off-road use and is extremely
sturdy. Nevertheless, please contact your authorized BIKEDRIVE dealer if any
malfunction should occur.

Please note: You are not entitled to perform any repair on the BIKEDRIVE. It does
not contain any user-serviceable parts.

After appropriate instruction by the specialized dealer you are permitted to
carry out the following described cleaning, inspection, and maintenance work.
Thereby, keep strictly to the instructions and be aware: A manipulation of the
bike that is equipped with a BIKEDRIVE carries a certain danger of getting
injured. Careless or irresponsible behavior or failure to follow the precaution­ary measures can cause the drive to start.

WARNING

Maintenance

Care & Maintenance

Risk of injury
Work on the bike can lead to serious injury!

Turn off the BIKEDRIVE and remove the battery before you commence with any
work, such as cleaning, maintenance, or troubleshooting!

2.1 Care & Maintenance

2.1.1 After each Ride

Cleaning with Water

Do not expose motor and battery to direct water spray!

1) Clean bike: Remove soiling using a damp rag.

2) Remove moisture: Rub dry motor, battery, cables, and plug connec-
tors with a soft cloth.

WARNING

Risk of injury
You must no longer use visibly damaged batteries. Continued use can lead to
serious injury!

• Remove the damaged battery from the battery rail!

• Do not connect the damaged battery to the battery charger!

• Discard the damaged battery in no case with normal household waste but
only to the appropriate official collection site or via your specialized dealer!

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Maintenance
Care & Maintenance

WARNING

Risk of injury
Wrong charging current or penetrating humidity can damage the battery and
can lead to serious injury!

• Use only an original BIKEDRIVE battery charger to recharge the battery!

• During the charging process, protect the battery, battery charger, and plug

• Do not carry out any cleaning or maintenance on the bike while charging is

• Do not leave charger and battery unattended during the charging process!

3) Check for damage: Check motor, battery, cables, and plug connectors
for external damage. Let your authorized BIKEDRIVE dealer replace
any damaged part immediately.

4) Check PowerGrip for ease of movement: It must automatically
bounce back when «Boost» is released. If this is not the case, you have
to dismount and let clean the PowerGrip (page 22).

connectors from contact with humidity (water, dew, cleaning agents, etc.) and
observe the permitted environmental conditions (
on page 35)!

ongoing!



section “3 Technical Data”

5) Charge battery: Choose a cool place to charge the battery. For infor­mation on charging temperature and duration see Table 6 on
page 38.

a) Connect battery charger with battery.

b) Connect battery charger to power outlet (100…240 VAC, 50…60 Hz)

and switch on.

c) Switch on battery. The charging process commences. Also observe

the following note «Remarks on the Charging Process».

d) Disconnect battery from battery charger.

e) Disconnect battery charger from power plug.

Remarks on the Charging Process

• The progress of the charging process is indicated by the battery LEDs. Thereby,
the currently level being charged flashes, the already charged levels light up
(



page 33).

• The battery may warm up during charging. If the specified charging temperature
range is exceeded, this is indicated by the battery charge indicator and charging
will be interrupted. After a cooling phase, charging will resume automatically. The
charging time can be prolonged.

• After reaching the full battery charge, the battery automatically shuts off. The
LEDs on the battery go out.

• The amber battery charger LED indicates that the battery charger is connected to
the battery. The LED lights up for the entire duration and after completion of the
charging process.

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Maintenance

Care & Maintenance

• The battery charger’s fan may automatically switch on and off during charging.

• If no battery is connected to the charger, the red battery charger LED lights up.

6) Store battery in a cool dry place. For example, do not let the battery
in your car when it is exposed to direct sunlight since it can get
extremely hot in a very short time! Also, observe the permitted envi­ronmental conditions (page 38)!

2.1.2 Storage of the Battery

Store the battery in a cool, dry place. For information on the maximum permit­ted storage temperature see Table 6 on page 38.

Long-term
storage

If you are not using the battery for extended periods, store it at approximately
60% of its capacity. A permanently higher charge will accelerate the principle­related natural aging of the battery.

2.1.3 Periodic Inspection

In addition to the maintenance specified by the bike manufacturer, you or your
authorized BIKEDRIVE dealer must perform the following inspections.

When? What?

After heavy use

Every 200 km
or
at least annually

Every 1000 km
or
at least annually

When not in use or
for storage:
Every 6 months

Brakes: Check wear on brake discs and brake pads,
replace if necessary

• Rear wheel: Check on specified spoke tension

• Quick-release axle: Check on specified torque

• Screw connections: Check for firm fit

• Plug connections: Check for firm fit

Battery rail: Check for firm fit

Battery: Fully charge the battery and disconnect from

battery charger. Then discharge to approximately 60%
(corresponds to approximately 3 of 5 battery LEDs).
Check the charge periodically and, if necessary, charge
anew and discharge it to 60%.

Table 2 Maintenance Plan

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Maintenance
Care & Maintenance

2.1.4 Replacing the rear Brake Disc

BIKEDRIVE axles are available in two designs; with quick-release lever or hexa­gon socket (Figure 5). For better legibility, in the further course only the quick­release version (A) will be shown.

Figure 5 Axle versions

2.1.4.1 Dismantling

Remove
cover

IMPORTANT

During disassembly, exposed parts can easily be damaged. Exercise caution.

1) Disconnect motor plug from
Power Cable.

2) Dismantle rear wheel.

3) Loosen and remove screws
(A).

4) Carefully pull off cover (B).

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Maintenance

Care & Maintenance

Fold down
cable

Loosen
set screw

Remove
torque lever

5) Carefully fold down cable (C)

by approx. 90°.

6) Loosen set screw (D) about 3

turns (do not remove!).

IMPORTANT

Do not damage cable.

7) Carefully pull off torque

lever (E) in axial direction
from hub by slightly weigh­ing back and forth. Put over
cable and plug and remove.

Remove
brake disc

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8) Loosen and remove screws

(H).

9) Remove spacer plate (G).

10) Carefully pull off brake disc.

Maintenance
Care & Maintenance

2.1.4.2 Reassembly

IMPORTANT

• During reassembly, parts can easily be damaged. Exercise caution.

• To attach the brake disc, use only the maxon «Brake Screw Kit TX25», the

• The screws must not axially touch the bottom of the tap. Wrong or too long

originally used, or as to below specified screws.

screws lead to permanent damage of the motor.

Use «Brake
Screw Kit
TX25»

or

check
dimensions

Mount
brake disc

RECOMMENDATION

Use maxon’s «Brake Screw Kit
TX25» (upper illustration).

If you decide not to use the
maxon screw kit:

Make sure that fastening screws
and washers correspond with
the indicated dimensions
(lower illustration)!

1) Check brake disc and hub for
cleanness, clean if necessary.

2) Observe specified brake
disc’s sense of rotation.

3) Slide brake disc (F) on hub,
align radially.

4) Mount spacer plate (G).

5) Mount screws (H) from
«Brake Screw Kit TX25» (for
others, apply medium
strength threadlocker first),
lightly tighten by hand.

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6) Turn brake disc against direc­tion of travel until it strikes
against screws.

7) Tighten screws crosswise
(torque 7 Nm).

Maintenance

Care & Maintenance

8) Align cable cutouts of torque

lever (E) and hub.

Mount
torque lever

Mount
set screw

Fold up cable

IMPORTANT

Do not damage cable.

9) Carefully put torque lever in

axial direction over cable
and plug, slide onto hub.

10) Radially align torque lever.

11) Carefully tighten set screw

(D). Do not apply thread­locker!

12) Carefully fold up cable (C) by

approx. 90° and insert into
groove.

Mount cover

13) Place cover (B) on torque

lever and align.

IMPORTANT

The cable must entirely rest in
the groove. It must not protrude
nor be pinched in the separating
pane.

14) Mount screws (A) and lightly

tighten.

15) Check cover for correct fit.

16) Tighten screws crosswise

until parts fully contact.

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Maintenance
Care & Maintenance

Install rear
wheel

17) Rotate rear wheel until
torque lever points in direc­tion of travel.

IMPORTANT

Do not damage cable.

18) Carefully position rear wheel
in dropout ans mount as fol­lows:

QR

• Lead axle from left through

the motor’s hollow shaft.

• Align rear wheel, hold tension

nut, and slightly tighten axle.

E-Thru threadless

• Insert tension nut in right

dropout.

• Insert axle from left through

the motor’s hollow shaft.

• Align rear wheel, slightly

tighten axle.

Mount stop­per sleeve

E-Thru / Flush / Maxle / X-12

• Screw tension nut in right

dropout, tighten by hand until
stop.

• Insert axle from left through

the motor’s hollow shaft.

• Align rear wheel, slightly

tighten axle.

19) Check condition of scratch
guard (illustration, circle),
replace if necessary.

20) Turn motor against direction
of travel until torque lever
strikes against frame from
below.

21) Tighten axle.

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Maintenance

Care & Maintenance

22) Check settings on derailleur

and rear wheel brake pads,
adjust if necessary.

23) Plug Power Cable to motor

plug and lock with bayonet
coupling.

Check
settings

24) Make sure that spring travel

are not restricted by the
cable.

25) Fasten Power Cable (but not

the motor plug!) to the
frame using cable ties.

26) Fasten motor cable to the

frame using «Power Cable
Strip».

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Maintenance
Care & Maintenance

2.1.5 Cleaning the PowerGrip

Heavy soiling can keep the PowerGrip from moving freely and can prevent it
from automatically bouncing back when «Boost» is released. In this case you
will need to dismantle and clean the PowerGrip. Your specialized dealer uses
for this purpose the «PowerGrip Service Tool» (533408), a special tool that you
may purchase.

2.1.5.1 Removing the PowerGrip

1) Loosen screw cap and unplug Control Cable from PowerGrip.

2) Loosen mounting screws on PowerGrip (and handlebar grip, if any).

3) Pull off handlebar grip and PowerGrip from handlebar.

2.1.5.2 Dismantling the PowerGrip

IMPORTANT

During disassembly, exposed parts can easily be damaged. Exercise caution.

Hold
PowerGrip

Position
«PowerGrip
Service Tool»

Lift off snap­in claws

1) Take the PowerGrip (A) with
one hand.

2) With the other hand, posi­tion the «PowerGrip Service
Tool» (B) right-angled at the
PowerGrip.

IMPORTANT

Ensure concentric position of the
parts.

3) Carefully push «PowerGrip
Service Tool» in axial direc­tion between snap-in claws
and twist grip while moving
slightly back and forth at the
same time.

22 maxon BIKEDRIVE | User Manual | rel7971

4) Insert «PowerGrip Service
Tool» up to the stop (approx­imately 1 mm deep) and hold
in this position.

Maintenance

Care & Maintenance

5) Hold firm housing (C).

Remove twist
grip

Align parts

6) Pull off twist grip (D)

together with «PowerGrip
Service Tool» in axial direc­tion from housing.

2.1.5.3 Cleaning

Now, you can clean the individual parts inside and outside:

• Clean housing with damp cloth, wipe dry afterwards.

• Clean twist grip with damp cloth or under running water, wipe dry
afterwards.

2.1.5.4 Reassembling the PowerGrip

1) Align housing and twist grip
as shown.

2) Slide twist grip (D) in axial

Mount twist
grip

Check proper
function

maxon BIKEDRIVE | User Manual | rel7971 23

direction on housing (C).

3) Press together both parts
until they lock with an audi­ble clicking sound.

4) Slightly twist both parts
against one another.

5) Check that twist grip rotates
smoothly and that all snap-in
positions engage easily.

Maintenance
Care & Maintenance

2.1.5.5 Mounting the PowerGrip

IMPORTANT

• You will need to shorten the right handlebar grip by about 23 mm if you

• When installed, the PowerGrip must freely rotate. It must thereby

wish both handlebar grips to be of identical lengths.

automatically bounce back when «Boost» is released.

1) Plug Control Cable to Power­Grip and tighten screw cap.

Mount
PowerGrip
and handle­bar grip

Fix
PowerGrip
and handle­bar grip

2) Slide PowerGrip and handle­bar grip on handlebar and
define their axial position.

3) Make sure that handlebar
grip touches the Power­Grip’s inner diameter, mount
plastics spacer if needed.

4) Turn PowerGrip radially into
an ergonomically comfort­able position.

5) Cautiously tighten mounting
screws on PowerGrip (and
handlebar grip, if any).

IMPORTANT

The PowerGrip must rotate
freely and must automatically
bounce back when «Boost» is
released.

24 maxon BIKEDRIVE | User Manual | rel7971

Maintenance

Care & Maintenance

2.1.6 Spare Parts

Through the combinations of the individual components – motor, freewheel,
end caps, and axle – the BIKEDRIVE can be mounted in a wide range of bike
designs and dropouts. The following overviews point out the possible combina­tions.

Note that the conversion is only possible within the motor variant. Thus, for
example, the motor «MX25» can be converted from a QR 135 axle to a TA-142
axle, however, a conversion to «MX25B» or «MXUrban» is not possible.

Spare parts are supplied by your specialized dealer.

WARNING

Risk of injury / damage to components
Installing a combination of non-harmonized components can result in serious
injury and damage to the bike!

• It is not permitted to mount a motor «MX25» or «MXUrban» into a Boost
dropout.

• It is not permitted to mount the motor «MX25B» into a standard dropout.

maxon BIKEDRIVE | User Manual | rel7971 25

Maintenance

(Table 3)

(Table 3)

Care & Maintenance

2.1.6.1 Compatibility Table

MX25

Figure 6 MX25 | Compatibility of Parts

26 maxon BIKEDRIVE | User Manual | rel7971

MX25B

(Table 3)

(Table 3)

Maintenance

Care & Maintenance

Figure 7 MX25B | Compatibility of Parts

maxon BIKEDRIVE | User Manual | rel7971 27

Maintenance

(Table 3)

(Table 3)

Care & Maintenance

MXURBAN

Figure 8 MXUrban | Compatibility of Parts

28 maxon BIKEDRIVE | User Manual | rel7971

Maintenance

Care & Maintenance

Battery

Motors

MX25

Axle

A B A+B A B A+B

QR 135/10 min. 5 min. 5 10.0…18.6 min. 5 min. 5 10.0…13.6

QR 141/10 min. 5 min. 5 18.2…28.6 min. 5 min. 5 13.2…23.6

Table 3 QR 135/10 — QR 141/10 | Min/Max Frame Dimensions [mm]

2.1.6.2 Spare Parts List

Designation

BX360 ONE 605854

BX500 ONE 582666

Baseplate 515431

Baseplate Plug Cover 535177

MX25-SG-AD-CH500 805005

MX25B-SG-AD-CH500 805008

MXUrban-SG-AD-CH600 623940

MXUrban

MX25B

Order

number

Continued on next page

maxon BIKEDRIVE | User Manual | rel7971 29

Maintenance
Care & Maintenance

Rear wheels,
fully fitted:

MX25
MXUrban

Designation

MX25-SG-AD-CH500-260DT01-N01-1KDT02
MXUrban-SG-AD-CH600-260DT01-N01-1KDT02

• Motor: as listed above

• Rim: DT Swiss 533d 26", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, single
crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

MX25-SG-AD-CH500-275DT01-N01-2KDT02
MXUrban-SG-AD-CH600-275DT01-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss 533d 27.5", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

MX25-SG-AD-CH500-280DT02-N01-2KDT02
MXUrban-SG-AD-CH600-280DT02-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss 545db 700c, black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

Order

number

607883
607915

607892
607919

607901
607919

Rear wheels,
fully fitted:

MX25B

MX25-SG-AD-CH500-290DT01-N01-2KDT02
MXUrban-SG-AD-CH600-290DT01-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss 533d 29", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

MX25B-SG-AD-CH500-275DT03-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss XM 481 27.5", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

MX25B-SG-AD-CH500-275DT04-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss XM 551 27.5", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

MX25B-SG-AD-CH500-290DT01-N01-2KDT02

• Motor: as listed above

• Rim: DT Swiss 533d 29", black

• Spokes: DT Alpine III Ø2.0/1.8/2.34 mm, black, dual crossed

• Spoke nipples: DT Pro Lock Squorx Pro Head, brass

607906
607921

607909

607911

607912

Continued on next page

30 maxon BIKEDRIVE | User Manual | rel7971

Maintenance

Care & Maintenance

PowerGrip

Battery
charger

Axles
(including
adapters)

Quick-

release lever

Hexagon

socket

Designation

PowerGrip dotX25 700025

PowerGrip dotX33 700033

PowerGrip dotXUrban 578492

Power Charger IV 623122

135 mm QR 135/10 (Table 3 on page 29) 512222

141 mm QR 141/10 (Table 3 on page 29) 541057

TA-142/148 E-Thru

TA-142/148 E-Thru threadless

142 mm
148 mm

TA-142/148 Flush

TA-142/148 Maxle

TA-142/148 X-12

Order

number

577735

573911

552063

544929

577736

573913

575894

573908

575893

573907

End caps

HG End Cap Kit 135/141 550001

HG End Cap Kit 142/148 580001

XD End Cap Kit 135/141 550002

XD End Cap Kit 142/148 580002

Continued on next page

maxon BIKEDRIVE | User Manual | rel7971 31

Maintenance
Care & Maintenance

Tools
and
Accessories

Designation

Stopper sleeve kit for torque lever 512275

Brake Screw Kit TX25 (for disc brakes) 519904

Brake Screw Kit TX25-CB (for Pedelec-compliant rim brakes) 546336

Control Cable 502867

Control Cable Extension 170 mm 521037

Control Cable Extension 250 mm 521040

Control Cable Extension 2000 mm 578187

Freewheel Kit HG 518374

Freewheel Kit XD 540562

Power Cable Strip 527842

PowerGrip Service Tool 533408

Allen wrench SW 1.27 573138

Table 4 Spare Parts

Order

number

32 maxon BIKEDRIVE | User Manual | rel7971

2.2 Troubleshooting

Cause: During shut down or after full discharge of the battery, the
deenergized condition of the motor will briefly be displayed at the

Display on
the
PowerGrip

Display on
the battery

PowerGrip.
Remedy: You do not need to do anything! For safety reasons, the power
supply will first be interrupted to the motor before the entire BIKEDRIVE will
be switched off.

Cause: The PowerGrip has detected an error in the system.
Remedy: Turn BIKEDRIVE off (page 6). Wait for one minute. Turn

BIKEDRIVE on.
Consult your specialized dealer if the error still should persist.

Flashing pattern: The LEDs flash once per second
Cause: Battery is in status «Safety condition overtemperature during

discharge».
Remedy: Turn BIKEDRIVE off (page 6). Wait for 15 minutes. Turn
BIKEDRIVE on.

Flashing pattern: The LEDs flash four times per second
Cause: Battery is in status «Safety shutdown during discharge».
Remedy: Check if battery is charged. Turn BIKEDRIVE off (page 6). Wait for
15 minutes. Turn BIKEDRIVE on.

Maintenance

Troubleshooting

Display on
the battery

Flashing pattern: The LEDs flash every 10 seconds
Cause: Error on the battery.
Remedy: Turn BIKEDRIVE off (page 6). Wait for 15 minutes. Turn

BIKEDRIVE on.
Consult your specialized dealer if the error still should persist.

Running lights: During the charging process, the LEDs display a running light
to the current charging level
Cause: The battery temperature is outside the permitted charging
temperature (Table 6 on page 38).
Remedy: If the ambient temperature is outside the charging temperature,
stop charging and resume at a suitably tempered location.
If the ambient temperature is within the charging temperature, you do not
need to do anything. Charging will continue automatically as soon as the
battery temperature is within the permitted charging temperature.

maxon BIKEDRIVE | User Manual | rel7971 33

Maintenance
Disposal

Motor does
not start

Cause: Battery empty.
Remedy: Recharge battery (page 14).

Cause: Main switch turned off.
Remedy: Turn BIKEDRIVE on (page 6).

Cause: Cable defective.
Remedy: Consult your specialized dealer.

Cause: Plug disconnected.
Remedy: Turn BIKEDRIVE off (page 6). Check plug connectors at motor,
battery, cables, and PowerGrip for firm fit. Turn BIKEDRIVE on.

Cause: Motor not correctly initialized.
Remedy: Turn BIKEDRIVE off (page 6). Push bike a step forward. Make sure
that wheels are not blocked. Turn BIKEDRIVE on.

Cause: Power-up with warm motor (for example after changing the battery).
Remedy: Wait 5 to 10 minutes to allow the motor to cool down.

Motor
rotates with
high speed or
in wrong
direction

2.3 Disposal

Cause: Motor not correctly initialized.
Remedy: Turn BIKEDRIVE off (page 6). Push bike a step forward. Make sure

that wheels are not blocked. Turn BIKEDRIVE on.

In no case dispose used components with normal domestic waste!

Dispose disused components only via official collection sites, point of sale, or
your BIKEDRIVE dealer! The sales price includes a prepaid disposal fee allowing
you to let dispose of and recycle disused components free of charge.

34 maxon BIKEDRIVE | User Manual | rel7971

3TECHNICAL DATA

The rating plate is located on the left side of the motor (as seen in direction of
travel).

Figure 9 Nameplate (typical)

Technical Data

Motor

Type

Nominal voltage 48 VDC

Output * 500 W500 W600 W

Torque * 26 Nm 26 Nm 19 Nm

Rotational speed * 183 rpm 183 rpm 290 rpm

Efficiency (maximal) 85%

Speed (maximal)

MX25 MX25B MXUrban

Brushless rotary current motor

PowerGrip

dotX25

25 km/h

(15.5 mph)

PowerGrip

dotX33

approx.

30 km/h

(18.6 mph)

PowerGrip

dotX25

25 km/h

(15.5 mph)

PowerGrip

dotX33

approx.

30 km/h

(18.6 mph)

PowerGrip
dotXUrban

approx.

40 km/h

(24.9 mph)

Weight approx. 3.5 kg (including hub)

Dimensions

Environmental
conditions

* according to UNECE regulation No. 85

electronically limited depending on battery voltage

Table 5 Motor MX25 / MX25B / MXUrban | Technical Data

maxon BIKEDRIVE | User Manual | rel7971 35

MX25 Figure 10

MX25B Figure 11

MXUrban Figure 12

Operating temperature −20…+50 °C
Storage temperature −20…+60 °C

Technical Data

depending on end cap version

Figure 10 Motor MX25 | Dimensions [mm]

depending on end cap version

Figure 11 Motor MX25B | Dimensions [mm]

36 maxon BIKEDRIVE | User Manual | rel7971

Technical Data

depending on end cap version

Figure 12 Motor MXUrban | Dimensions [mm]

maxon BIKEDRIVE | User Manual | rel7971 37

Technical Data

Battery

Type

Nominal voltage 48 VDC

Nominal charge 7.5 Ah 10.4 Ah

Nominal capacity 360 Wh 500 Wh

Charging time (0…100%) 2 h 3.5 h

Weight 2.7 kg 2.8 kg

Dimensions (LxWxH) 285x86x120 mm

Environmental
conditions

* with increased charging temperature up to approx. 5.5 h

Table 6 Battery BX360 ONE / BX500 ONE | Technical Data

BX360 ONE BX500 ONE

Lithium-ion battery

Operating temperature

−20…+60 °C −20…+50 °C

Charging temperature

0…+45 °C +10…+40 °C

Storage temperature

0…+30 °C

Figure 13 Battery BX360 ONE / BX500 ONE | Dimensions [mm]

38 maxon BIKEDRIVE | User Manual | rel7971

Baseplate

Baseplate

Type

Weight 435 g

Table 7 Baseplate | Technical Data

Battery mount, comprising adapter, base, battery

rail, and Power Cable

Technical Data

Figure 14 Baseplate | Dimensions [mm]

PowerGrip

Type

Weight 56 g

Table 8 PowerGrip | Technical Data

Figure 15 PowerGrip | Dimensions [mm]

PowerGrip

Electronic throttle grip

maxon BIKEDRIVE | User Manual | rel7971 39

Technical Data

Battery Charger

Type

Nominal voltage 100…240 VAC, 50…60 Hz

Output voltage 54.6 VDC

Charging current 5 A typical

Weight 1.4 kg

Dimensions (LxWxH) 189x90x65 mm

Operating temperature −10…+40 °C
Environmental
conditions

Table 9 Power Charger IV | Technical Data

Storage temperature: −20…+65 °C

Humidity 5…65% (non-condensing)

Indoor use only

Power Charger IV

Quick charger

Figure 16 Power Charger IV | Dimensions [mm]

40 maxon BIKEDRIVE | User Manual | rel7971

Accessories (approximate weights)

QR 135/10 75 g

QR 141/10 81 g

Technical Data

Axles

Quick-release lever

Hexagon socket

End caps

Freewheel Kits

TA-142/148 E-Thru

TA-142/148 E-Thru threadless

TA-142/148 Flush

TA-142/148 Maxle

TA-142/148 X-12

HG End Cap Kit 135/141 13 g

HG End Cap Kit 142/148 16 g

XD End Cap Kit 135/141 13 g

XD End Cap Kit 142/148 16 g

Freewheel Kit HG 100 g

Freewheel Kit XD 85 g

120 g

120 g

125 g

125 g

120 g

120 g

120 g

120 g

120 g

120 g

Control Cable (L=700 mm) 15 g

Control Cable
Extension 170 mm

Cables

Table 10 Accessories | Technical Data

Control Cable
Extension 250 mm

Control Cable
Extension 2000 mm

6 g

7.5 g

56 g

maxon BIKEDRIVE | User Manual | rel7971 41

Technical Data

••page intentionally left blank••

42 maxon BIKEDRIVE | User Manual | rel7971

Index

Index

A

accessories 32
accessories (technical data) 41
air transport 11

B

Baseplate (battery mount)

technical data 39

battery

charging level 8
discharge 10
storage 15

technical data 38
battery charger (technical data) 40
brake disc, replacement of 16
BX (technical data) 38

C

care 13
charging indicator 8
cleaning 13
components 3

D

dimming (display) 7
discharge of battery 10
displays 7
disposal 34
driving mode

description 4

display 7

F

faults, elimination of 33
functional principle 4

I

IATA (regulations for air transport) 11
identification (PowerGrip) 7
indications used 3
influencing factors (battery charge) 10
inspection, periodic 15

L

labeling 3
legal regulations 4
legislation 4
lock 6

M

main switch 6
maintenance 13
motor

reduced power 9

technical data 35
motorized assistance 4
MX (technical data) 35

N

nameplate 35

O

operating range 10

P

periodic inspection 15
Power Charger (technical data) 40
PowerGrip

cleaning 22

functional principle 5

identification 7

technical data 39
power-up 6
propulsion mode 4
pushing aid 4

R

range 10
reduced motor power 9
references used 3
regulations, legal 4
runtime (battery) 10

S

spare parts 25
status indicator 8
storage 15
switch on/off 6
symbols and signs used 3

T

technical data 35
theft protection 6
tools 32
transport 11
troubleshooting 33
turn off 6

maxon BIKEDRIVE | User Manual | rel7971 43

The present document is protected by copyright. Any use (including reproduction, translation,
microfilming, and other means of electronic data processing) without prior written approval is
not permitted. The mentioned trademarks belong to their respective owners and are pro­tected under intellectual property rights.

© 2018 maxon advanced robotics & systems. All rights reserved. Subject to change without
prior notice.

maxon BIKEDRIVE | User Manual | Edition 2018-03 | Document ID rel7971

maxon advanced robotics & systems Ltd..
Industriestrasse 24
CH-6074 Giswil
Switzerland

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