Page 1
TECHNICAL MANUAL
BLUE PAPER
KERAM
BOSCH GEN4
2020
Page 2
BLUE PAPER KERAM BOSCH GEN4 20202 | ORBEA ORBEA | 3 TECHNICAL MANUAL
INDEX
GEOMETRY & ERGONOMY 4
TECHNICAL SPECIFICATIONS 6
HEADTUBE AND HEADSET 8
REAR DERAILLEUR 9
PROTECTORS 10
CABLING 13
BOSCH GEN4 MOTOR ASSEMBLY 15
INTERNAL BATTERY ASSEMBLY 16
DUAL BATTERY ASSEMBLY 17
MAINTENANCE 20
ORBEA WARRANTY 22
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GEOMETRY & ERGONOMY
BLUE PAPER KERAM BOSCH GEN4 20204 | ORBEA ORBEA | 5 TECHNICAL MANUAL
SIZE S-27,5” M-29” L-29” XL-29”
1 - Seat tube (c-t) 400 405 457 515
2 - Top tube (eff ) 538 569 603 638.4
3 - Head tube 105 114 133 158
4 - Chainstay 475 475 475 475
5 - Bb height 307 313 313 313
6 - Bb drop 43 63 63 63
7 - Wheelbase 1112 1149 1173 1210
8 - Head angle 67º 67º 68º 68º
9 - Seat angle 73º 73º 73º 73º
10 - Standover heigh 798 825 861 893
11 - Reach 355 375 402 430
12 - Stack 600 636 659 752
13 - Fork leng th 518 530 530 530
* The headtube angle measurement on MTB, A sphalt and Comfort models may change slightly depending on the
travel of the fork specicated.
HEIGHT (CM) HEIGHT ( IN) SIZE
150-165 59.1”-65.0” S-27. 5”
165 -175 65.0”-68.9” M-29”
175 -18 5 68.9”-72.8” L-2 9”
185-195 72.8”-76.8” XL-2 9”
* The sizing measurements are orientative.
Page 4
TECHNICAL SPECIFICATIONS
NOTE: This technical document describes the Keram
models (MTB, Asphalt and Comfort) equipped with
a Bosch Gen4 motor. For 2019 and onwards models
equipped with a previous generation Bosch motor,
consult the technical document Bluepaper Keram 2019
from the manuals section of the Orbea´s website.
BLUE PAPER KERAM BOSCH GEN4 20206 | ORBEA ORBEA | 7 TECHNICAL MANUAL
FRAME MATERIAL
INTENDED USE MTB: CROSS COUNTRY, TRAIL
SIZES S,M,L,XL
FORK TRAVEL MTB: 100MM O 120MM
WHEEL SIZE 700C-29"
MAX. TYRE SIZE 29"X2.4
FORK OFFSET 42MM OR 51MM. DEPENDING ON MODEL
BOTTOM BRACKET MOTOR BOSCH GEN4
HEADSET INTEGRATED 1 1/8-1 1/2
REAR AXLE STANDARD 135MM X 9MM QR
SEATPOST DIAMETER 31.6M M
SEATPOST CLAMP DIAMETER 34,9MM SPECIFIC KERAM 19 FRAME
FRONT DERAILLEUR N/A. 1X ONLY
CHAINRING MAXIMUM SIZE 38T
ALUMINUM
ASPHALT: URBAN, LEISURE
COMFORT: URBAN, LEISURE
ASPHALT: RIGID FORK
COMFORT: 63MM
CHAINGUIDE
ICGS NO
CABLING INTERNAL (FULL SLEEVE)
LEFT-ROAD CABLING READY
BOTTLE HOLDER 1. ALL SIZES
COMPATIBLE DI2 NO
COMPATIBLE SRAM AXS YES
DRIVETRAIN COMPATIBILITY 10, 11 AND 12 SPEED
COMPATIBILIDAD POTENCIÓMETRO NO
INTERNAL BATTERY YES. IN DOWNTUBE. 400WH OR 500WH. BOSCH POWERPACK
DUAL BATTERY OPTION
MOTOR
DISPLAY BOSCH PURION
MOTOR ASSEMBLY ANGLE 6,5º
YES. ALL CABLES ENTER THE FRAME
YES. ONLY AS A COMPLETE OPTION AT THE MOMENT
OF PURCHASE. NOT COMPATIBLE WITH SIZE S FR AME
ONLY BOSCH GEN4 AND GEN3
(USES DIFFERENT MOTOR MOUNTING PL ATES)
NO
ON THE LEFT SIDE
MAXIMUM CRANK LENGHT 170MM
BRAKES DISCO POST MOUNT *
REAR ROTOR MX. SIZE 180MM
REAR ROTOR MIN. SIZE 160MM
* Not all calipers and rotors in the market are compatible with all frames.
All componets specicated from Orbea have been tested. For aftermarket options, check componentes
dimensions and tolerances before purchasing.
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BLUE PAPER KERAM BOSCH GEN4 20208 | ORBEA ORBEA | 9 TECHNICAL MANUAL
HEADTUBE AND HEADSET REAR DERAILLEUR
Ø 46
Ø 42
3
45º
7.5
Ø 52.1
Ø 56
HEADSET 1 1/8-1 1/2 INTEGRATED (INCLUDES TOPCAP AND STARNUT)
KIT Nº: Y0000127 QUANTITY
HEADSET 1 1/8-1 1/2 INTEGRATED
1
1 1/8 LOWER BEARING ADAPTOR (FOR 1 1/8 STRAIGHT STEERER TUBE FORKS)
ART Nº: 14031591 QUANTITY
1 1/8 LOWER BEARING ADAPTOR
1
1.1
13.1
13.2 1.2
QR STANDARD REAR DER. HANGER
01 KIT Nº: Y0000117 QUANTITY
1.1
QR STANDARD REAR DER. HANGER
1.2
BOLT M4x9
1
2
QR DIRECT MOUNT REAR DER. HANGER
13 KIT Nº: Y0000118 QUANTITY
13.1
QR DM REAR DER. HANGER
13.2
BOLT M4x9
1
2
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PROTECTORS
BLUE PAPER KERAM BOSCH GEN4 202010 | ORBEA ORBEA | 11 TECHNICAL MANUAL
KERAM 19 SEATPOST CLAMP
02 ART Nº: 11160252 QUANTITY
2
KERAM 19 SEATPOST CLAMP
1
LEFT CHAINSTAY PROTECTOR
03 KIT Nº: Y0000224 QUANTITY
3.1
LEFT CHAINSTAY PROTECTOR
3.2
BOLT M4x25
7.5
7.4
7.2
7.3
RIGHT CHAINSTAY PROTECTOR
04 KIT Nº: Y0000225 QUANTITY
4.1
RIGHT CHAINSTAY PROTECTOR
4.2
BOLT M4x25
1
1
1
1
CHARGING PORT RUBBER PROTECTOR
7.1
4.1
20
1 Nm
4.2
5
3.1
6
05 ART Nº: 11000468 QUANTITY
CHARGING PORT RUBBER PROTECTOR
1
BATTERY KEYHOLE RUBBER PROTECTOR
06 ART Nº: 11000467 QUANTITY
BATTERY KEYHOLE RUBBER PROTECTOR
1
BATTERY COVER KIT
1 Nm
20
3.2
07 KIT Nº: Y0000226 QUANTITY
7.1
BATTERY COVER KERAM 19 BLACK
7.2
BATTERY COVER LOCK MALE
7.3
BATTERY COVER LOCK FEMALE
7.4
WASHER 4,5mm
7.5
WASHER M6
1
1
1
1
1
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BLUE PAPER KERAM BOSCH GEN4 202012 | ORBEA ORBEA | 13 TECHNICAL MANUAL
CABLING
8.2
Rear derailleur
8.1
M4
1 Nm
8.3
9.1
9.2
8.4
M4
1 Nm
8.3
KERAM BOSCH GEN4 MOTOR PROTECTOR
08 KIT Nº: Y0000223 QUANTITY
8.1
RIGHT MOTOR PROTECTOR
8.2
LEFT MOTOR PROTECTOR
8.3
BOLT M4x10
8.4
BOLT M4x60
Display
Rear brake
Double battery connec-
9.1
tion cable. Use Bosch
Y split cable. Cut motor
protector to allow cable
to pass.
Internal battery cable. Use
Bosch Y split cable for double
battery installations.
Speed sensor
KERAM 19 CABLEGUIDE KIT
09 KIT Nº: Y0000227 QUANTITY
1
1
4
1
9.1
RUBBER GROMMET 2mm 22x8
9.2
RUBBER GROMMET 5mm 30x10
2
1
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ALL CONNECTIONS ARE MADE ON THE NON-DRIVE
SIDE OF THE MOTOR
BLUE PAPER KERAM BOSCH GEN4 202014 | ORBEA ORBEA | 15 TECHNICAL MANUAL
BOSCH GEN4 MOTOR ASSEMBLY
Below the left chainstay
to speed sensor xing point.
To front on the bike throught
downtube to display.
To internal battery´s downtube lower connector.
10.4
10.3
10.10
10.6
10.7
10.9
10.1
10.8
10.2
10.5
10.8
10.5
10.8
10.8
TORQUE SETTING: 30Nm
Battery cable
connector
HMI connector: Display
Speed sensor
connector
BOSCH GEN4 MOTOR ASSEMBLY KIT
10 KIT Nº: Y0000228 QUANTITY
10.1
BOSCH G4 ASSEMBLY PLATE LONG LEFT
10.2
BOSCH G4 ASSEMBLY PLATE LONG RIGHT
10.3
BOSCH G4 ASSEMBLY PLATE SHORT LEFT
10.4
BOSCH G4 ASSEMBLY PLATE SHORT RIGHT
10.5
NUT M8
10.6
BOLT M8x55
10.7
BOLT M8x50
10.8
BOLT M8x16
10.9
TOOTHED WASHER M8
10.10
SPACER 20.2mm
1
1
1
1
4
2
2
6
4
2
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BLUE PAPER KERAM BOSCH GEN4 202016 | ORBEA ORBEA | 17 TECHNICAL MANUAL
INTERNAL BATTERY ASSEMBLY
11.3
11.1
11.6
11.4
DUAL BATTERY ASSEMBLY
The complete external battery connection kit is only available as an option when purchasing a
keram from Orbea.
For bikes that were purchased with the internal battery only, Orbea will facilitate the compo-
nents that are Orbea´s own and specic to the Keram frame for the installation of the external
battery. These items are included in the kit Y0000230.
The electric components, like cables and powerpack battery brackets, as well as the locks, may
be purchased through a Bosch or Abus distributor. These components are in the next page.
Contact your Abus and Bosch ebike dealer to know the exact list of components needed for the
installation of a powerpack dual battery system.
The installation of these components needs an advanced mechanical and electrical knowledge
and can only be performed by a certied Orbea dealer.
The use of a dual battery requires the electric system to be updated for the correct operation of
all components. This update must be carried out by a Bosch ebike dealer.
The dual battery option is not compatible with size S Keram frames.
The aftermarket assembly of the dual battery option is only compatible with Keram frames
equipped with a Bosch Gen4 motor. Orbea cannot guarantee the components compatibility on
Keram frames with a Bosch GEN3 motor.
11.2
11.5
INTERNAL BATTERY ASSEMBLY HARDWARE KIT
BOSCH OR ABUS COMPONENTS NOT INCLUDED.
11 KIT Nº: Y0000229 QUANTITY
11.1
THREADED BATTERY LOWER MOUNT PLATE
11.2
SPACER 6,5mm LOWER BATTERY MOUNT
11.3
BOLT M5x18
11.4
BOLT M5x30
11.5
M5 SQUARE NUT
11.6
RUBBER ALLEN BOLT HEAD COVER
1
1
2
2
2
4
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BLUE PAPER KERAM BOSCH GEN4 202018 | ORBEA ORBEA | 19 TECHNICAL MANUAL
12.3
12.2
12.10
12.9
12.4
12.8
12.5
DUAL BATTERY ASSEMBLY HARDWARE KIT
BOSCH OR ABUS COMPONENTS NOT INCLUDED
12 KIT Nº: Y0000230 QUANTITY
U SHAPED TOP BATTERY BRACKET SPACER 1
12.1
12.2 BOTTLE HOLDER PLATE DUAL BATTERY 1
12.3 THREADED PLATE BOTTLE HOLDER 1
12.4 BOLT M5x20 2
12.5 BOLT M5x45 2
12.6 M5 SQUARE NUT 2
12.7 M5 TOOTHED WASHER 1
12.8 BOLT M5x15 BOTTLE HOLDER 2
12.9 THREADED BATTERY LOWER MOUNT PLATE 1
12.10 SPACER 6,5mm LOWER BATTERY BRACKET. 1
* Not included. Already on bike or on internal battery hardware kit.
12.7
12.6
12.1
It is necessary to cut the motor protector
To allow clearance for the external battery cable.
ABUS COMPONENTS REFERENCE DESCRIPTION
POWERPACK LOCK PLUS + KEY
When ordering the new lock, facilitate your abus distributor the
Key number on your wild fs so the new lock is made to match the key,
Enabling you to use the same key for both batteries.
BOSCH COMPONENTS REFERENCE DESCRIPTION
STANDARD BATTERY CABLE 1.270.015.067 Battery Cable Standard
LOWER POWERPACK BATTERY HOLDER LEFT
SCREW 3,5x12 (x2)
ALUMINUM BRACKET HOLDER
BATTERY BRACKET BOLT (x2)
PLASTIC CASING LOCK TOP
PLASTIC CASING LOCK BOTTOM
SCREW 3,5x12 (x1)
BOLT M5x12 (x2)
CABLE "Y" DUAL BATTERY 515/430mm
CHARGING SOCKET BLANK PLUG (x2)
TAPÓN PIN SOPORTE BATERÍA
33261 BLO BOS DT2 PLUS
0.275.007.425 Battery holder kitLOWER POWERPACK BATTERY HOLDER RIGHT
0.275.007.426
1.270.020.605
0.275.007.930
Mounting set for bracket
battery frame
Kit plastic casing lock
frame
Bosch Dual Battery
Y-Adapter kit
Page 11
MAINTENANCE
BLUE PAPER KERAM BOSCH GEN4 202020 | ORBEA ORBEA | 21 TECHNICAL MANUAL
Orbea products are carefully designed to be long-lasting,
efcient and easy to maintain. The carbon and aluminum
frames on the Keram are extremely corrosion-resistant.
However, your Orbea bicycle needs regular maintenance
of its components in order to work properly and to ensure
their longevity.
1) KEEP YOUR KERAM CLEAN
Washing your bike with mild soap and water will keep you
looking stylish and allow you to check the condition of the
frame and components. Don’t use high water pressure and
avoid spraying water into bearings or frame tubes. Citrus
degreasers are biodegradeable and do a great job of remo-ving dirty grease from gears and chain.
2) KEEP YOUR KERAM LUBED
Once your bike is clean, it’s a good time to put fresh lube
on the chain. Use only enough to get inside the links and
wipe off any excess because it will attract dirt. Headset
and pivot bearings should be inspected every few months
for smoothness and to ensure that the seals are intact and
lube is clean.
3) INSPECT YOUR KERAM BEFORE
YOU RIDE
Do a quick check before every ride to make sure your bike
is in excellent condition. It is very common to discover
small issues at home that can become big problems on the
trail. CHAIN Is the chain dirty, noisy or dry? Clean and lube
your chain before riding. BRAKES Check your brakes to
make sure they are working correctly. Check for missing/
loose caliper and rotor bolts. TIRES Look for damage to
the sidewalls of your tires. Check and adjust tire pressu-re.
WHEELS Spin the wheels and look for wobbles, check
for loose or broken spokes. Check quick release levers
to make sure they are functioning properly. FRONT END
Stand over the saddle, pull on the brakes and rock the bike
back and forth. Feel for any play or knocking that might
indicate a loose headset, loose brake rotors or calipers, or
worn fork bushings.
TEST RIDE Take a quick ride up and down the street to
make sure your bike is shifting and braking properly. Listen for unusual noises.
4) BEARINGS
Bearings are one element subject to wear and tear. They
must be in good condition to ensure that the other parts
of the bicycle work correctly: on the wheels, the steering
column and the bottom bracket.
Regularly check to make sure that the bearings turn freely
in their housing and there are no signs of lateral play. Bearings that do not turn properly or that have any lateral play
must be replaced immediately in order to prevent wear
and tear to the parts of the frame. Very damp weather
conditions can cause the bearings to wear out faster. Avoid
washing your bicycle with pressurized water hoses. If you
have any questions, take your bicycle to an Orbea dealer
for correct diagnosis and maintenance.
5) BOSCH EBIKE ELECTRIC SYSTEM
Ebikes´ electric systems use complex electronic components that require your attention. Always read the available documentation before using your ebike and follow the
recommended use and maintenance instructions.
This documentation will allow you to get the maximum
performance out of your ebike.
To know more about the Bosch system on your Keram,
go to:
https://www.bosch-ebike.com/
AFTER A CRASH OR IMPACT
Falling is part of riding and it’s impossible to avoid minor
accidents. If you crash your Keram, please make sure you
are okay and seek medical attention if necessary. If you
are not injured, you should check your bike before continuing:
1) Inspect your frame and components for damage.
Do not ride your bike if any problems are detected.
WHAT TO LOOK FOR
Inspect Frame and fork for evidence of cracking or bending. If cracks are discovered, discontinue use immedia-tely.
Check the drivetrain and spin the wheels to make sure
components are operating correctly. If you discover
da-mage to your components, discontinue use immediately.
Even if you don’t nd any damage, pay careful attention
to the sound of your bike when you continue riding. Unusual noises can be caused by cracks or other problems.
A well-maintained bike will be quiet and free of creaks or
squeaks. Investigate and locate the source of any new
noises.
2) Bring your bike to your Orbea dealer for professio-nal inspection. Some damage can only be detected
by disassembling the bike to check for cracks or other
signs of stress.
A crash or impact can put extraordinary stress on your
bike and components, causing them to fail or to fa-tigue prematurely. Failure can happen suddenly with
no warning, causing loss of control, serious injury or
death.
Page 12
BLUE PAPER KERAM BOSCH GEN4 202022 | ORBEA ORBEA | 23 TECHNICAL MANUAL
ORBEA WARRANTY
The constant effort we make every day to produce the
highest quality bicycles enables us to offer the following
warranty and coverage conditions:
LEGAL WARRANTY
Orbea guarantees its products by law for a period of 2
years or whatever has been stipulated as the legal warranty period in the country where the purchase was made, to
the original owner of the bicycle/component.
This warranty covers Orbea products against manufactu-ring defects and/or lack of conformity and guarantees
the repair or replacement of the defective product at no
cost to the affected customer. Likewise, this warranty also
co-vers paint, varnish and corrosion defects on all frames
and rigid forks assembled on our bicycles during the pe-
riod specied in the rst paragraph of this warranty.
This warranty does not cover in any case damage derived
from misuse or the lack of maintenance, or from the normal wear and tear of perishable parts, such as, but not
limited to: seals, bearings, handlebar tape, spokes, hub,
threads, tires, seat, etc.
See the full description of the coverage and the legal
warranty conditions at:
https://www.orbea.com/int-en/warranty-benets/
ORBEA LIFETIME WARRANTY
As a complement to the legal warranty, Orbea offers the
original buyer of the bicycle, under the condition of having registered their bicycle on the Orbea website within a
period of 30 days following its purchase, the Orbea Li-fetime Warranty, which covers the frames and rigid forks
we assemble on our bicycles, with no time limit, against
manufacturing defects.
This warranty extends the original period of coverage
against pain, varnish or corrosion defects on our frames
and rigid forks for one additional year after the end of the
legal warranty period.
See the full description of the coverage and the Lifetime
Warranty conditions at:
https://www.orbea.com/int-en/warranty-benets/
REGISTER YOUR BICYCLE
In order to benet from the extension of the Orbea Lifeti-me Warranty, register your bike within the rst 30 days
of having purchased it at www.orbea.com
01. REGISTER YOUR ACCOUNT
02. REGISTRATION NUMBER
03. WHERE TO FIND YOUR NUMBER
2
1
3
1
2
3
WARRANTY CLAIM PROCESS
All warranty claim processes must be processed through
an Orbea dealer, who will provide the company with the
necessary documentation for the diagnosis of said claim.
The dealer will inform the customer of the decision made
by Orbea.
BOSCH EBIKE PRODUCTS
Bosch ebike components are covered by a two year
warranty from the moment of purchase. Consult the
complete warranty terms and conditions on https://www.
bosch-ebike.com/
For any question or claim about the Bosch system on your
Wild HT, contact your Orbea dealer.
ADDITIONAL INFORMATION
ORBEA participates actively on facebook and Twitter with
our fantastic global community of riders. Looking to nd
spots to ride or plan a vacation? Someone will have the
answers:
FACEBOOK
www.facebook.com/OrbeaBicycles
TWITTER
www.twitter.com/Orbea/
YOUTUBE
Visit our Orbea Channel on You Tube for a variety of helpful
setup and tech videos:
www.youtube.com/user/OrbeaBicycles
INSTAGRAM
www.instagram.com/orbeabicycles
ORBEA CONTENT
View and download photos, videos and documents.
content.orbea.com/us-en/
BLOG ORBEA
www.orbea.com/es-es/blog/
YOUR ORBEA DEALER
Our dealers are experts and should be able to assist you
with setting up and maintaining your Orbea bicycle. A
com-plete listing of Orbea dealers and distributors can be
located on our website:
www.orbea.com/us-en/dealers/?country=INT
SUPPORT
For technical questions about Orbea products, write to:
For any other question:
Page 13
WWW.ORBEA.COM
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