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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