User Manual
I General User Manual
English
II User Manual | Fast Pedelec
*
III User Manual | Pedelec with centre motor
IV User Manual | Pedelec with ont motor
V User Manual | Pedelec Impulse
VI User Manual | Pedelec Groove
*
*
VII User Manual | BionX
VIII User Manual | Bosch
*
Not included in this document.
*
Raleigh Univega GmbH 2012
*
*
General
User Manual
English
I
Raleigh Univega GmbH 2012
1 The bike and its components
1 Handlebar
2 Handlebar stem
3 Bell
4 Headset
5 Front light
6 Mudguard
7 Fork
8 Front wheel brake
9 Tyres
10 Wheels
11 Bottom bracket
12 Pedals
13 Chain
14 Rear derailleur
14 a Front derailleur
14 b Rear derailleur
15 Rear light
16 Reector
17 Pannier rack
18 Saddle
3
19 Frame
18
2
4
17
15
16
6
10
14b
13
9
14a
11
19
6
12
8
1
5
7
10
9
2 I General User Manual
2 Preface
Your bike has been delivered to you lly assembled.
If parts of your bike have not been installed, please consult your specialist cycle shop.
The purpose of this User Manual is to help you use your
bike safely in the manner for which is is intended, and enjoy all its benets for many years to come. We assume that
you have general knowledge on the handling of bikes.
Every person who uses, cleans, maintains or disposes of
this bike must have read and understood the entire content of this User Manual.
In addition to texts, tables and lists, the User Manual contains the following symbols that denote important information or dangers.
WARNING about possible physical injury,
increased risk of falls or other injuries
IMPORTANT ADDITIONAL INFORMATION or
special information on using the bike
NOTE about possible damage to property or
the environment
I General User Manual 3
3 Content
1 The bike and its components 2
2 Preface 3
3 Content 4
4 Safety information 7
4.1 Basic safety information 7
4.2 For your own safety 7
4.3 Information for parents and legal guardians 7
4.4 Safety in road trac 7
4.5 Bike safety 8
5 Legal provisions 8
5.1 Applicable road trac licensing regulations 8
6 Intended use 9
6.1 General information 9
9.2.4 Adjusting the saddle angle 15
9.2.4.1 With a two-bolt seatpost 15
9.2.4.2 With a seatpost saddle clamp 15
9.2.4.3 With a suspension seatpost 16
9.3 Adjusting the handlebar position 16
9.3.1 Adjusting / aligning the handlebar height
with a conventional handlebar stem 16
9.3.2 Adjusting the handlebar height with
A-head systems 17
9.3.3 Aligning handlebars with A-head systems
in relation to the ont wheel 17
9.3.4 Adjusting the handlebar position by
turning the handlebar 17
9.3.5 Adjusting the handlebar height with
an adjustable handlebar stem 18
6.2 Trekking bike / all-terrain bike (ATB), if
equipped in accordance with the applicable
road trac licensing regulations 9
6.3 City, touring, sports, child's and
youngster's bike, if equipped in accordance
with the applicable road trac licensing
regulations 9
6.4 Mountain bike (MTB) / cross bike 10
6.5 Road bike / tness bike 10
6.6 BMX 10
7 Before the rst ride 11
8 Before every ride 12
9 Setting up the bike for the rider 12
9.1 Fitting the pedals 12
9.2 Adjusting the seat position 13
10 Frame 18
11 Headset 19
12 Fork 19
13 Suspension ame and suspension elements 20
13.1 Frame with rear suspension 20
13.2 Care and maintenance 20
14 Bottom bracket and cranks 21
15 Checking the bottom bracket 21
16 Wheels 21
16.1 Checking the wheels 21
16.2 Checking the hubs 21
16.3 Checking the rims 22
17 Tyres and inner tubes 22
9.2.1 Adjusting the bike saddle 13
9.2.2 Operating the quick-release device 13
9.2.3 Determining the correct saddle height 14
4 I General User Manual
17.1 Tyres 22
17.2 Tubeless tyres 23
17.3 Tubed tyres 23
17.4 Inner tubes 23
18 Repairing a puncture 24
20 Bike chain 40
18.1 Opening the brake 24
18.1.1 Opening the cantilever or V-brake 24
18.1.2 Removing the hydraulic rim brake 24
18.1.3 Opening the side-pull calliper brake 25
18.1.4 Releasing the hub gears, roller, drum
or back-pedal brakes 25
18.2 Removing the wheel 25
18.2.1 Removing the ont wheel 25
18.2.2 Removing the rear wheel 25
18.3 Removing the tyre and inner tube 26
18.4 Mending the inner tube 26
18.5 Fitting the tyre and inner tube 27
18.6 Fitting the wheel 27
18.6.1 Inserting the ont wheel 27
18.6.2 Inserting the rear wheel 27
18.6.2.1 Bikes with derailleur gears 27
18.6.2.2 Bikes with hub gears 27
19 Bike gears 30
19.1 Derailleur gears 30
19.1.1 Operating the shiing lever 31
19.1.1.1 Shiing lever on road bike 31
19.1.1.2 Shiing lever on MTB, trekking
and touring bike 35
20.1 Maintenance of bike chains 40
21 Brake, brake levers and brake systems 41
21.1 Important information and precautionary
measures 41
21.2 Brake lever 42
21.2.1 Standard brake lever 42
21.3 Hub brakes 42
21.3.1 Drum and roller brakes 42
21.3.2 Back-pedal brake 43
21.4 Rim brakes 44
21.4.1 Readjusting the brake 44
21.4.2 Adjusting the brake-pad clearance
in relation to the rim 44
21.4.3 Wear of brake pad 45
21.5 Disc brakes 45
21.5.1 Hydraulic disc brake 46
21.5.2 Vapour bubble formation 47
21.5.3 Cleaning the brake system 47
21.5.4 Fitting/removing the wheel 47
22 Lighting system 48
22.1 Specications for lighting system 48
22.2 Special regulations for road bikes 48
22.3 Generator / dynamo 48
19.2 Hub gears 38
19.2.1 Operating the hub gears 38
19.2.1.1 Shimano 7/8-speed shi lever 38
19.2.2 Adjusting gears with Shimano
hub gears 39
22.3.1 Sidewall dynamo 48
22.3.1.1 Switching the sidewall dynamo
on and o 48
22.3.2 Hub dynamo 49
22.4 Failure of the lighting system 49
I General User Manual 5
23 Add-on components 50
27.5 Brake pads 58
23.1 Pannier rack 50
23.1.1 Front pannier rack 50
23.1.2 Rear pannier rack 50
23.2 Wheel guards / mudguards 51
23.2.1 Re-engaging the safety-release
mechanism 51
24 Accessories and equipment 52
24.1 Child seat 52
24.2 Bike stand 53
24.3 Bike trailer 53
24.4 Bike basket 53
24.5 Bar ends 53
25 Bike carriers for mounting on roof and rear of car 54
26 Carbon components 54
27.6 Brake discs 58
27.7 Bike chains or toothed belts 58
27.8 Chainrings, sprocket wheels and jockey
wheels 58
27.9 Lamps of lighting set 58
27.10 Handlebar tapes and handle grips 59
27.11 Hydraulic oils and lubricants 59
27.12 Gear-shi and brake cables 59
27.13 Paint nishes 59
27.14 Bearings 59
27.15 Sliding bearings and bearings for llsuspension ames, suspension forks
or other suspension elements 59
28 Regular inspections 60
28.1 Inspection schedule 60
26.1 Properties 54
26.2 Torques 54
26.3 Visual inspection 55
26.4 Carbon ame 55
26.5 Carbon handlebar 55
26.6 Carbon handlebar stem 55
26.7 Carbon wheels 56
26.8 Carbon fork 56
26.9 Carbon seatpost 56
26.10 Splinters 56
26.11 Fastening in mounting stand 56
26.12 Transportation by car 56
27 Care and maintenance of the bike 57
28.1.1 Maintenance / checks 60
29 Link list 61
30 Technical data 62
30.1 Maximum permitted gross weight of bike 62
30.2 Maximum permitted loading of pannier rack
63
30.3 Tightening torques for screw connections 63
30.3.1 General tightening torques for screw
connections 65
30.4 Tyres and tyre pressure 65
30.5 Lighting set 65
31 Warranty conditions 66
31.1 Prerequisites for the validity of warranty
claims 66
27.1 Care 57
27.2 Wear parts 57
27.3 Tyres 58
27.4 Rims in conjunction with rim brakes 58
6 I General User Manual
31.2 Warranty exclusions 66
4 Safety information
4.1 Basic safety information
Please read all the warnings and information in this User
Manual carelly before using the bike. Keep this User
Manual near your bike for ready reference.
If you hand this bike over to someone else, don't forget to
give them the User Manual as well.
4.2 For your own safety
› Always use a suitable bicycle helmet and wear it
correctly.
4.3 Information for parents and legal
guardians
› Make sure that your child has been taught, and
also understands, how to handle the bike safely
and responsibly in the environment in which it is
going to be used.
› Explain to your child how to operate all the
brakes, and also how they work and any special
features. For rther important information on
this matter, refer to ➠
levers and brake systems".
› As the legal guardian, you are responsible for the
safety of your child and any damage he/she may
cause when cycling. You should therefore make
absolutely sure that the bike is in technically
sound condition and adjust it regularly to the
size of the child.
Chapter 21 "Brake, brake
› Wear bright clothing or reective elements so
that other road users can see you in good time.
› Wear shoes with a sti, and whenever possible,
non-slip sole.
› Wear close-tting clothing on your legs, or wear
trouser clips.
› Wear protective clothing such as robust shoes
and gloves.
4.4 Safety in road trac
› Observe the applicable trac regulations.
› Never ride with no hands!
› In some countries children below a certain age
must ride on the pavement and must also dismount when crossing the road. Please familiarise
yourself with the applicable regulations.
› Adjust your handling on wet or slippery roads;
ride more slowly and brake carelly and in good
time as you will require a much greater braking
distance.
› Adopt a speed that reects the terrain as well as
your riding ability.
› Do not listen to music through headphones when
cycling.
› Do not cycle when using a mobile phone.
› Use designated cycle paths when not using pub-
lic roads.
I General User Manual 7
› Be ready to brake, especially if you are not sure
what lies ahead or are riding downhill.
4.5 Bike safety
› Only bikes that have been approved for use in
public places, as per the applicable regulations
(e.g. StVZO in Germany), may be used.
› Observe the maximum permitted gross weight of
the various bike types, as this could otherwise
lead to breakage or failure of safety-relevant
components. The brake system is also only designed for the maximum permitted gross weight
of the bike. For a list of the maximum permitted
gross weights, refer to ➠
data".
The gross weight is the sum of the weight
of the bike + weight of the rider + weight of the
luggage. The gross weight also includes towed
weights such as trailers.
› If you notice that a part is damaged or warped,
do not use the bike until you have had the part
replaced as otherwise parts that are important to
operation of the bike may fail.
› Observe the maximum load-carrying capacity of
the pannier rack. This is marked on the pannier
rack directly (also refer to ➠
cal data").
Chapter 30 "Technical
Chapter 30 "Techni-
Bear in mind that with intensive use of your bike wear
increases accordingly. Many bike parts, particularly
on light sports bikes, are only designed for a specic
period of use. If this is exceeded, there is a considerable risk that components could fail.
Perform care and maintenance on your bike regularly.
In doing so, check important components, particularly
the ame, fork, wheel suspension, handlebar, handlebar stem, seatpost and brakes for warping and damage. If you notice changes such as cracks, bulges or
warping, have your bike checked by a specialist cycle
shop before using again.
5 Legal provisions
If you wish to use your bike in road trac, make sure that
your bike complies with the road trac regulations. If
necessary, observe ➠
road bikes".
5.1 Applicable road trac licensing
regulations
Before you take your bike on the road, nd out what the
relevant national regulations in your country are – in
Germany, these are the Road Trac Licensing Regulations
(StVZO) and the Road Trac Ordinance (StVO).
In Switzerland, the applicable regulations can be found
in the Ordinances relating to Technical Requirements for
Road Vehicles, Articles 213 to 218.
Chapter 22.2 "Special regulations for
› Have maintenance and repairs carried out by a
professional bike workshop (for maintenance
intervals, refer to ➠
tions").
› If you make technical changes to your bike, take
the national trac regulations and applicable
standards into account. Bear in mind that this
could render your warranty invalid.
› Only replace electrical components on your bike
with type-tested parts.
› Only ride with suitable lighting in unfavourable
lighting conditions such as fog, rain, dawn/twilight or in the dark.
8 I General User Manual
Chapter 28 "Regular inspec-
If you wish to ride in road trac in Austria, you must observe Ordinance 146 / Bicycle Ordinance.
Make sure each time you use your bike that it actually is
in the prescribed roadworthy condition, that the brakes
are properly adjusted and that the bell and lighting set
comply with the relevant regulations in your country, in
Germany these are the Road Trac Licensing Regulations
(StVZO).
In some EU countries, battery-operated ont lights and
rear lights may only be used by road bikes weighing less
than 11 kg. They must always be carried and have an ocial approval (sinuous line and K number). All other bikes
must use dynamo lighting sets. Every component of the
system must carry the ocial test mark which identies it
as "approved". The applicable regulations in your country
apply in this regard, e.g. the Road Trac Licensing Regu-
lations (StVZO) in Germany. When performing technical
modications, bear in mind that electrical components
must only be replaced by type-tested components.
6 Intended use
6.1 General information
Bikes are a means of transportation for one person. In
some countries, regulations exist governing the carrying
of passengers, such as the Road Trac Ordinance (StVO)
in Germany (tandem or bike child seat).
6.2 Trekking bike / all-terrain bike
(ATB), if equipped in accordance
with the applicable road trac
licensing regulations
If you wish to carry luggage, you will require a suitable
xture on your bike. Bear in mind the maximum loadbearing capacity of the carrier (see ➠
cal data").
Not every bike type is suitable for every surface. Bikes are
not designed to cope with extreme stresses such as jumping or riding over steps.
You must not take part in competitions with your bike. The
only exceptions to this are bikes that are oered explicitly
for use in competitions.
The information in this User Manual applies for all bike
types.
Any deviations for individual bike types are identied
accordingly.
Observe the relevant user manual om the individual
component manufacturers which can be found on the CD
or in the Internet. If you have any questions once you
have read the documentation, your specialist cycle shop
will be pleased to provide assistance.
Chapter 30 "Techni-
You may use these bikes on surfaced routes and in road
trac, providing they are equipped accordingly. They are
also suitable for gentle ooad riding, such as on country
lanes.
The manufacturer and cycle shop will not accept liability
claims
should the bike not be used as intended
ticularly applies for non-observance of the safety information and damage resulting for example om:
• overloading or
• incorrect repairs.
. This par-
6.3 City, touring, sports, child's and
youngster's bike, if equipped in
accordance with the applicable road
trac licensing regulations
Intended use also includes compliance with the operating,
maintenance and repair instructions provided in this User
Manual.
The manufacturer and cycle shop will not accept liability
claims should the bike not be used as intended.
You can use these bikes in road trac and on surfaced
routes.
The manufacturer and cycle shop will not accept liability
claims
should the bike not be used as intended
ticularly applies for non-observance of the safety information and damage resulting (for example) om:
• ooad use,
• overloading or
• incorrect repairs.
I General User Manual 9
. This par-
6.4 Mountain bike (MTB) / cross bike
The bike is exempt om these requirements for the duration of ocially approved cycling events.
The manufacturer and cycle shop will not accept liability
claims should the bike not be used as intended. This particularly applies for non-observance of the safety information and damage resulting for example om:
• ooad use,
• overloading,
You can use these bikes ooad. You must not use these
bikes in road trac or competitions. If you wish to use
your bike on public roads, it must have the requisite
equipment features (see ➠
The manufacturer and cycle shop will not accept liability
claims should the bike not be used as intended
This particularly applies for non-observance of the safety
information and damage resulting for example om:
• use in competitions,
• overloading,
• incorrect repairs.
• riding over steps,
• jumping,
• riding through deep water
• extreme stresses on non-designated MTB routes or
MTB courses.
Chapter 5 "Legal provisions").
.
• incorrect repairs or
• use in competitions,
6.6 BMX
These bikes are designed for BMX routes and/or BMX practice facilities.
In some EU countries, they are not approved for use in
road trac, e.g. by the Road Trac Licensing Regulations
(StVZO) in Germany, and in this case must not be used for
this purpose (see ➠
wear a helmet and protective clothing, such as elbow and
knee pads.
The brakes normally installed on BMX bikes produce a
less eective braking action. You should therefore bear in
mind that this increases the braking distance, especially
in wet conditions. Please test this thoroughly in a safe
location and always adjust your handling accordingly.
The manufacturer and cycle shop will not accept liability
claims should the bike not be used as intended
Chapter 5 "Legal provisions").Always
.
6.5 Road bike / tness bike
You may use these bikes on public roads for training purposes. You may use road bikes weighing up to 11 kg without permanently tted dynamo lighting. If you choose to
do so, you must carry a battery-operated ont light and a
rear light. If the light has the required approval, there will
be an embossed sinuous line and K-number on it.
When using road bikes that weigh more than 11 kg in road
trac, the required equipment features must be installed.
Please familiarise yourself with the applicable regulations.
This particularly applies for non-observance of the safety
information and damage resulting for example om
• use in competitions,
• overloading,
• incorrect repairs.
• riding over steps or
• jumping.
10 I General User Manual
7 Before the rst ride
Make sure that your bike is ready for use and is set up
for your body size.
Check the following:
• Positioning and secure fastening of saddle and
handlebar
• Installation and correct adjustment of the brakes
• Secure fastening of wheels in ame and fork
Adjust the handlebar and stem until you nd a safe
and comfortable riding position. Instructions on how
to adjust the handlebar are provided in ➠
"Adjusting the handlebar position".
Adjust the saddle until you nd a safe and comfortable riding position. Instructions on how to adjust the
saddle are provided in ➠
seat position".
Chapter 9.2 "Adjusting the
Chapter 9.3
Never inate the tyres to less than the minimum or
more than the maximum specied tyre pressure. As a
rule of thumb, e.g. when on the road, you can check
the tyre pressure as follows: If you press your thumbs
into the inated tyre, there should not be much give
in the tyre even if you press hard.
Check the tyres and rims for damage, foreign bodies,
e. g. glass agments or sharp stones and deformation.
If cuts, cracks or holes are visible, do not ride o. Instead, take your bike to a professional bike workshop
and have it checked.
Make sure the brake levers are always within easy
reach and that you know how to operate the right/
le brake levers and where to nd them. Make a note
of which brake lever operates the ont and which the
rear wheel brake.
Modern brake systems can have a far more powerl
and dierent braking eect than those you are already
familiar with. Before setting o, familiarise yourself
with the eects of the brakes on a safe trac-ee
area.
If you are using a bike with carbon-bre rims, bear
in mind that the braking behaviour of this material is
much poorer than aluminium rims.
Make sure that the wheels are securely fastened in the
ame and forks. Check that the quick-release device
and all important fastening screws and nuts are securely fastened.
➠
Chapter 9.2.2 "Operating the quick-release device"
contains instructions on how to operate quick-release
devices safely and ➠
tains a table of the tightening torques for important
screws and nuts.
Chapter 30 "Technical data" con-
Check the tyre pressure. Information on the prescribed tyre pressure appears on the tyre sidewall.
I General User Manual 11
8 Before every ride
Although a great deal of care has been taken during
production and assembly, parts may still come loose
or change nction during transportation for example.
You should therefore always check the following before every ride:
• Bell and lighting are working properly and se-
curely fastened
• Brake system is working properly and securely
fastened
• If a hydraulic brake is tted to your bike, make
sure the lines and connections are tight
• Check the tyres and rims for damage and foreign
bodies and check the wheel runs true, especially
aer riding ooad
9 Setting up the bike for the rider
Road bikes or mountain bikes can also be supplied without pedals.
Proceed as follows if you wish to t pedals to your bike
yourself:
9.1 Fitting the pedals
› Coat both pedal threads with lubricant (grease).
The le pedal has a le-handed thread which is normally indicated by an "L" embossed on the axle. The
right pedal has a right-handed thread which is normally indicated by an embossed "R".
• Sucient tread depth on the tyres
• The suspension elements are in working order
and are securely fastened
• Screws, nuts and quick-release devices are se-
cure
• Frame and fork for deformation and damage
• Handlebar, handlebar stem, seatpost and saddle
in the correct position and safely and properly
secured
If you are not sure whether your bike is in a technically sound condition, do not ride it and have it checked
by a professional bike workshop instead.
Axle with right pedal thread Axle with le pedal thread
› Screw the le pedal anticlockwise into the le
crank.
› Screw the right pedal clockwise into the right crank
(on the side of the bike chain).
› Tighten both pedals using a suitable size15
open-ended spanner or Allen key. Tighten all
screws to the prescribed torque (➠
"Technical data"). If you do not do this, the pedals may come loose.
Chapter 30
12 I General User Manual
Make sure you t or screw in the pedals straight, as
otherwise you could damage the thread in the crank
arm beyond repair.
1
1 MTB system pedals
2 Touring or sports pedals
3 Road bike system pedals
2
3
9.2 Adjusting the seat position
9.2.1 Adjusting the bike saddle
The seat position is decisive for your well-being and cycling performance.
› Do not remove or change the seatpost or saddle
clamp. If you change or modi components, this
renders the warranty invalid.
› Tighten all screws to the prescribed torque as
otherwise screws could shear o and components could come loose or detach altogether (see
➠
Chapter 30 "Technical data").
Only use the designated cleats and shoes for MTB,
racing and system pedals. If you use other cleats/
shoes you may slip out of the pedals.
Riders who are inexperienced in the use of MTB system
pedals or road system pedals, also referred to as click
pedals, are vulnerable to falls with potentially serious
consequences. If you use system pedals, practise clicking
into the pedal and releasing the shoe om the pedal when
the bike is stationary. Never practise this in road trac.
Read the user manual of the pedal and shoe manufacturer.
You can also nd more information on this subject in
the Internet. A list of links is provided in ➠ Chapter 29
"Link list" .
Only work on the bike if you have the correct tools
and requisite knowledge. Always have complex or
safety-relevant work carried out by a specialist cycle
shop.
9.2.2 Operating the quick-release device
› All quick-release devices must be tightened se-
curely before you set o. Check this before every
journey.
› If you leave your bike unattended, check that all
quick-release devices are correctly secured before setting o again.
› When closing the quick-release lever to lock it,
it must be necessary to apply a force that causes
you to make a st with your hand as otherwise
the quick-release device could come loose.
I General User Manual 13
Quick-release device
2
1
1 Quick-release lever
2 Adjusting nut
To open the quick-release device, proceed as follows:
› Throw back the quick-release lever so that its inner
face or the lettering OPEN is visible.
› Open the quick-release device as far as possible.
› When closed, quick-release levers must lie at
against the ame, fork and saddle clamp. Make
sure that quick-release devices for the hubs point
backwards when closed as otherwise they could
snag on obstructions when the bike is moving
and open. This could lead to serious accidents.
9.2.3 Determining the correct saddle height
› Sit on the bike saddle.
› Try to reach the pedal with your heel when it is in
the bottom position. Your knee should be more or
less lly straightened out.
› Place the balls of your feet on the centre of the
pedal. If your knee is now slightly bent, the saddle
height is correct.
› Turn the adjusting nut anticlockwise to rther
slacken the quick-release device.
To close the quick-release device, proceed as follows:
› Adjust the clamping strength by turning the adjust-
ing nut.
› If the quick-release device closes too easily, open
it again and turn the adjusting nut clockwise.
› If the quick-release device still closes too easily,
repeat the previous step.
› If the quick-release device is too dicult to close,
turn the adjusting nut anticlockwise.
› Turn back the quick-release lever om the OPEN
position so you can see the outer side of the lever
or the lettering CLOSE.
Never tighten the seatpost if the maximum mark or
stop mark is above the top of the seat tube as otherwise you could injure yourself or damage the seatpost. Always observe the specied tightening torques.
In ll-suspension mountain bikes the seat tube is also
open at the bottom, so the seatpost should only be inserted a certain distance downwards to ensure the rear swing
arm and suspension element never come into contact
when the bike is in use.
14 I General User Manual
9.2.4.1 With a two-bolt seatpost
The minimum insertion depth is marked on the seatpost. If this is not the case, the minimum insertion
depth must be 7.5 cm. In ames with long seat tubes
that project beyond the top tube, the minimum insertion depth is 10 cm.
Observe stop
mark.
9.2.4 Adjusting the saddle angle
› Your bike saddle should be as close as possible to
horizontal.
› You can make use of longer bike rides to nd out
what your most comfortable seat position is. If you
want to tilt the saddle, try tilting it very slightly
forwards. If you tilt the saddle back, this can quickly lead to pain or physical injury.
Some seatposts have two screws for adjusting the saddle angle, one in ont of and one behind the seat tube.
If you want to tilt the saddle forwards, loosen the rear
screw with an Allen key and tighten the ont screw by the
same number of revolutions. To tilt the saddle backwards,
loosen the ont screw and tighten the other to the same
degree. Then retighten both screws observing the correct
tightening torque (see ➠
Chapter 30 "Technical data").
Two-bolt seatpost
9.2.4.2 With a seatpost saddle clamp
If the saddle is attached to the seatpost by a clamp, the
clamping nut will be at the side. Adjust the saddle angle
as follows:
› Turn the clamping nut anticlockwise to loosen it.
You may need to counter the nut on the other side
using another wrench.
Adjust the saddle angle as follows:
› Turn the clamping screw anticlockwise to loosen it.
› Tilt the bike saddle to the required angle.
› Turn the clamping screw clockwise to tighten it.
(For tightening torques see ➠
data").
Chapter 30 "Technical
Adjusting the saddle angle
› Tilt the bike saddle to the required angle.
› Turn the clamping nut clockwise to tighten it. You
may need to counter the nut on the other side using another wrench. Use the correct tightening
torque (see ➠
Chapter 30 "Technical data").
Seatpost saddle clamp
I General User Manual 15
9.2.4.3 With a suspension seatpost
Suspension seatposts reduce vibrations caused by uneven
roads thereby reducing stress on the spinal column.
If you need to adjust the suspension elements in the seatpost, consult your specialist cycle shop.
Suspension seatpost
› Bend your upper body towards the handlebar until
you have found a position that is comfortable for
your back.
› Stretch out your arms towards the handlebar.
› Note the approximate position of your hands and
set the handlebar at this height.
9.3.1 Adjusting / aligning the handlebar
height with a conventional handlebar
stem
To release the stem sha in the head tube, proceed as
follows:
› Release the stem expander bolt to loosen the han-
dlebar stem. Turn it anticlockwise by two or three
revolutions using an Allen key.
9.3 Adjusting the handlebar position
Tighten all screws to the prescribed torque as otherwise screws could shear o and components could
come loose or detach altogether (see ➠
"Technical data").
You can also inuence your riding position by changing
the handlebar height.
The lower you set the handlebar, the rther you will have
to lean forwards. This increases the strain on your wrists,
arms and upper body and you will need to bend your back
rther.
The higher the handlebar is, the more upright your riding
position will be. This increases the stress on your spinal
column due to jolting.
Chapter 30
› Clamp the ont wheel between your legs to pre-
vent the bike fork om turning with the stem sha.
› Holding the handlebar by the handles, turn it om
right to le and vice-versa.
› If it is not possible to do this, tap lightly on the
stem expander bolt with a plastic hammer to loosen the clamping xture inside the stem.
› Set the handlebar stem to the required height.
› Align the handlebar so that it is exactly at right
angles to the ont wheel.
› To secure the stem sha again, turn the stem ex-
pander bolt clockwise using an Allen key until it is
tight (see ➠
Chapter 30 "Technical data").
You can determine a handlebar height that best suits your
body size as follows:
› Sit on the bike saddle.
› Ask another person to hold the bike steady if
required.
16 I General User Manual
Never tighten the handlebar stem if the maximum
mark or stop mark is above the top of the sha. If you
cannot nd a mark, insert the handlebar stem into
the head tube to a depth of at least 6.5 cm. If you do
not do this, the handlebar stem could come loose or
break.
9.3.2 Adjusting the handlebar height with
A-head systems
With the A-head stems shown here, the handlebar height
must be adjusted by a professional bike workshop.
9.3.3 Aligning handlebars with A-head
systems in relation to the ont wheel
To align the handlebar with the ont wheel, proceed as
follows:
› Loosen the hexagon socket screws on the rear of
the handlebar stem by turning them anticlockwise
with an Allen key.
9.3.4 Adjusting the handlebar position by
turning the handlebar
Loosen the hexagon socket screws on the ont of the
stem. Turn the handlebar until you nd the position that
is comfortable for you. Make sure that the handlebar is
always exactly in the centre of the stem. Now retighten the
hexagon socket screws by turning them clockwise. If the
tightening torque is stamped on the stem, use this value,
and if not, use the tightening torques in ➠
"Technical data".
Once you have adjusted the handlebar, you will also need
to adjust the brake levers and gear-shi handles. Loosen
the hexagon socket screws on the handle grips. Sit on
the saddle and put your nger on the lever. Turn the lever until your hand and lower arm are in a straight line.
Retighten the screws in the handle grips by turning them
clockwise. (For tightening torques see ➠
nical data").
Chapter 30
Chapter 30 "Tech-
› Turn the handlebar so that it is exactly at right
angles to the ont wheel.
› Tighten the hexagon socket screw by turning it
clockwise with an Allen key (see ➠
"Technical data").
Chapter 30
I General User Manual 17
9.3.5 Adjusting the handlebar height with an
adjustable handlebar stem
With some types of handlebar stems, you can vary the
handlebar tilt. The stem angle can be adjusted via the
clamping screws which are on the side of the articulation
or the top/bottom of the stem. Models equipped with additional stop notches or adjusting screws are available.
Adjusting screw
Hexagon socket screw
(integrated stop notch)
Adjust the handlebar tilt as follows:
10 Frame
The form of the ame depends on the bike type and nction. Frames are manufactured om dierent materials
– steel or aluminium alloys or carbon (carbon bre), for
example.
The ame number of the bike is stamped on the seat
tube, the dropout or the bottom bracket housing.
› Undo the clamping screw by turning it anticlock-
wise through two or three revolutions using an
Allen key.
› If you own a model that is also equipped with
detents, continue turning the clamping screw anticlockwise to disengage the detents.
› If you own a model with integrated stop notch,
loosen the screw of the stop notch. In many stem
types this is located on the underside of the stem.
› Tilt the handlebar stem to the required angle.
› To fasten the handlebar stem, tighten the clamping
screw clockwise using an Allen key . If tightening
torques are specied on the stem, use exactly these
torques, and if not, refer to the table of tightening
torques in ➠
› In models with an integrated stop notch, tighten
the screw of the stop notch carelly clockwise.
In doing so, the stop notch must engage with the
teeth.
Chapter 30 "Technical data".
It may also be found on the motor suspension in Pedelecs. The bike can be identied by the ame number if it is stolen. To identi the bike properly, it is
important to note down the whole number in the right
order.
Never ride your bike if the ame is warped or
cracked. On no account should you attempt to repair
damaged parts. This can lead to accidents. Replace
defective parts before you ride the bike again.
Aer an accident or crash, have your bike checked by
a professional bike workshop before riding it again. If
defects on the ame or components go unnoticed this
can lead to accidents.
If your bike does not roll forwards easily in a straight
line, this could mean that the ame is warped. In this
case, have the steering stability checked by a professional bike workshop.
18 I General User Manual
11 Headset
12 Fork
Headset
The headset is the bearing for the bike fork in the ame. If
the headset has been properly adjusted, it will turn easily.
In doing so, no play should be evident.
The headset is subject to a large amount of stress due to
impacts with the road surface. This can cause it to come
loose or aect its setting. Have the play and ease of movement of the headset checked regularly by your specialist
cycle shop (for inspection intervals see ➠
"Inspection schedule").
Checking the headset
Chapter 28.1
The ont wheel is held in place by the bike fork. The bike
fork consists of two fork blades, the fork crown and steering tube.
Carbon fork Suspension fork
The suspension fork is a feature of most mountain bikes,
trekking bikes and city bikes. They can be adjusted in
dierent ways and provide a greater degree of riding comfort.
For information on the nction, maintenance and care of
suspension elements, refer to ➠
ame and suspension elements". Specic information on
your suspension fork is provided in the manufacturer's
operating instructions which you can nd on the CD or the
manufacturer's website.
Chapter 13 "Suspension
If you do not adjust the headset properly or tighten
it too tightly, this could cause breakages. This should
therefore always be carried out by a professional bike
workshop.
If you ride with the headset loose, this could damage
the bearing shells or fork.
Never ride with a damaged bike fork. Do not attempt
to repair a defective bike fork. This can lead to serious
accidents. If you notice that the bike fork is warped or
otherwise damaged, replace it before using the bike
again.
Avoid sudden changes in ground level and riding o
high kerb stones. This can damage the fork and lead
to serious accidents.
Check regularly that the screws on the bike fork are
securely fastened. If screws are allowed to come
loose, this can cause serious accidents.
I General User Manual 19
13 Suspension ame and suspension
elements
response, but does not strike through if you ride over an
obstruction. It must give slightly when you sit on your
bike.
13.1 Frame with rear suspension
If you wish to ride ooad in a particularly sporty manner
or with a high degree of comfort, you may have opted for a
ll-suspension model. In this case, the rear triangle of the
main ame is not rigid; instead it can move and is spring
mounted and damped by a shock absorber.
Full-suspension ame
Dierent types of suspension elements are used. These
are mainly shock absorbers equipped with a steel spring
or an air chamber whose air is compressed due to the
action of the suspension. In high-quality shock absorbers,
the damping action, that regulates the speed of compression and rebound, can be adjusted. This task is performed
by a system of oil chambers and ducts.
Although this type of shock absorber oers a higher degree of riding safety and comfort, it requires special handling. This User Manual contains only general information
in this regard. Detailed information and advice is provided
in the instructions om the shock absorber manufacturer
enclosed with the CD and can also be obtained om your
specialist cycle shop.
13.2 Care and maintenance
You can clean your ll-suspension MTB in the usual manner. Hot water with a little washing-up liquid or a gentle
detergent which you can obtain om your specialist cycle
shop are suitable for this.
You should avoid using a high-pressure cleaner to
clean your bike as the cleaning uid can also enter
sealed bearings due to the high pressure and damage
them beyond repair.
You should carelly wipe down the piston of the shock absorber and the seal with a so cloth as part of your regular
bike maintenance. If you spray a little spray oil, e.g. om
Brunox, on the running surface of the shock absorber and
the seal, this increases its performance and service life.
You should regularly check the articulations of the rear
triangle for play. To do this, li the wheel and try to move
the rear wheel sideways.
You can detect play in the mounting bushes of the shock
absorber by liing the rear wheel up and setting it back
down quickly. If you sense play or hear a rattling noise,
have your bike checked immediately by a professional
bike workshop.
Your safety depends to a large extent on whether the
suspension elements are securely fastened and are
working correctly. You should therefore regularly look
aer and inspect your ll-suspension bike.
The website of the relevant suspension element
manufacturer may also prove to be a valuable source
of information. Informative and helpl links are provided in ➠
Your specialist cycle shop should have adjusted the suspension for you before handing over your new bike. Your
bike and the seat position may look dierent to what you
are used to, and may also feel dierent when you are riding. The spring strut must be tuned so that it has a so
20 I General User Manual
Chapter 29 "Link list".
› Tighten all screws to the prescribed torque as
otherwise screws could shear o and components could come loose or detach altogether (see
➠
Chapter 30 "Technical data").
14 Bottom bracket and cranks
Chainrings are wear parts. Their service life depends on
various factors, e.g.
• maintenance and care,
• type of use and
• distance travelled.
15 Checking the bottom bracket
16 Wheels
16.1 Checking the wheels
The wheels connect the bike with the surface you are riding on. The wheels are subject to a particularly high level
of stress due to unevenness of the riding surface and the
weight of the rider.
The wheels are carelly checked and trued prior to delivery. However, the spokes may settle when you ride the
rst kilometres on your bike.
› Have the wheels checked again and trued if neces-
sary aer the rst 100 kilometres by a specialist
cycle shop.
The cranks must be securely fastened as this could
otherwise damage the crankset.
› The cranks can come loose which is why you should
regularly check whether they are securely fastened
by attempting to rock them to and o.
› If there is play in the cranks, have the bike checked
and the cranks fastened securely by a professional
bike workshop .
If your bike has a carbon ame and a bottom bracket
housing for a BB30 bottom bracket please note the
following:
In this case you can t an adapter so that a bottom
bracket with conventional BSA thread can be used.
However, bear in mind
• You can only install the adapter if the ame is
completely undamaged. Repairing a defective
BB30 housing serves no purpose. If it is not
installed correctly, the bottom bracket housing
may be damaged which would render the warranty void. This kind of adapter should only be
tted by a specialist cycle shop.
› You should subsequently regularly check the ten-
sion in the spokes and have loose or damaged
spokes replaced, and/or have the wheel trued, by a
specialist cycle shop.
The wheel can be attached to the ame and fork in a number of dierent ways. In addition to the standard systems
in which the wheel is held on by axle nuts or quick-release
devices, dierent types of oating axles exist. These can
be held in place by a screw connection or dierent types
of quick-release devices. If your bike has a oating axle,
please also refer to the enclosed manufacturer's user manual or visit the web pages of the relevant manufacturer in
the Internet.
Tighten all screws to the prescribed torque as otherwise screws could shear o and components could
come loose or detach altogether (see ➠
"Technical data").
Chapter 30
• Once the adapter has been tted in the carbon
ame it cannot be removed.
16.2 Checking the hubs
To check the hub bearings, proceed as follows:
› Li the wheel and spin it.
› Check whether the wheel continues to turn through
several revolutions before it stops moving. If it
stops suddenly, the bearing is damaged. This does
not apply for ont wheels with hub dynamos.
› To determine whether there is play in the hub bear-
ing, try rocking the wheel in the bike fork or rear
I General User Manual 21
triangle backwards and forwards perpendicular to
the direction of travel.
17 Tyres and inner tubes
› If you notice that there is play between the bear-
ings or if you encounter resistance when turning
the wheel, have the hub bearing adjusted by a specialist cycle shop.
16.3 Checking the rims
If you are using a rim brake, the rim is subject to a higher
degree of wear.
If a rim is worn it loses stability which makes it
more susceptible to damage. If the rim is deformed,
cracked or broken this can lead to serious accidents.
If you notice changes in a rim on your bike, do not
ride on it. Have the problem checked by a professional bike workshop.
17.1 Tyres
A large number of dierent tyre types exist. The bike's
ooad capability and rolling resistance depend on tread
prole.
Only inate the tyre to the maximum permissible tyre
pressure as otherwise it may burst.
Inate the tyre at least to the specied minimum air
pressure. If the tyre pressure is too low, the tyre may
detach om the rim.
The maximum permissible tyre pressure, and normally
also the minimum permissible pressure, can be found
on the tyre sidewall.
Always replace the tyre with a tyre of the same type,
dimension and prole as otherwise the ride characteristics may be adversely aected. This can lead to
accidents.
Rims for bikes with wheel sizes greater than 24" are
supplied with a rim wear indicator. These rims have
a characteristic curve or groove that runs round the
entire circumference.
Replace the rim as soon as you notice marks (grooves,
coloured spots) in one location on the rim, if an
embossed marking has disappeared or if a coloured
marking has worn down.
If the marking consists of a groove or several points
on the rim side wall, have the rim replaced as soon as
it wears o.
Tyres are wear parts. Check the tread depth, tyre pressure and condition of the tyre sidewalls regularly.
Replace worn tyres before using the bike.
Note the dimension of the tted tyre. Standard designations are used when stating the tyre dimension.
• Example 1: "46-622" means the tyre is 46mm
wide and the rim diameter is 622mm.
• Example 2: "28 × 1.60 inches" means that the tyre
diameter is 28 inches and the tyre width is 1.60
inches.
22 I General User Manual
The tyre pressure is equently stated in PSI. ➠ Chap-
ter 30 "Technical data" contains a table which you can
use to convert tyre pressures om PSI into bar.
17.2 Tubeless tyres
Tubeless tyres are also used nowadays, especially with
modern mountain bikes, but also with road bikes to a lesser extent. Although the oer a number of benets, they
must be used and handled with caution.
Only use tubeless tyres on suitable rims. These are
identied accordingly, e.g. using the abbreviation
"UST".
Only use tubed tyres on the designated rims. These do
not have turned-up edges (rim anges) and instead
have a smooth inwards-curving surface onto which
the tubed tyre is glued.
Only use the tubed tyres of the prescribed type and in
the prescribed manner with the correct tyre pressure.
Special skills and a great deal of experience are
required to glue on tubed tyres. Always have tubed
tyres replaced at a professional bike workshop. Find
out how to handle tubed tyres correctly and how to
replace them safely.
Only use tubeless tyres of the prescribed type and in
the prescribed manner, with the right tyre pressure
and, if applicable, using the recommended sealing
uid.
Tools must not be used to remove tubeless tyres om the
rim as otherwise leaks may subsequently occur. If the
sealing uid does not remedy the defect, the valve can be
removed and a normal inner tube used.
17.3 Tubed tyres
Tubed tyres are also used, particularly on bikes used in
sports competitions. With this tyre type, the inner tube
is sewn into the casing and this unit is glued rmly to the
designated rim using special adhesive. Tubed tyres oer
enhanced safety in the event of a puncture and improved
emergency-running characteristics
17.4 Inner tubes
The inner tube is necessary to maintain the pressure inside the tyre. It is inated via a valve.
Three valve types exist:
1
1 Sclaverand or road valve
2 Schrader or car valve
3 Dunlop or Woods valve
2 3
All three have a cap to protect them om ingress of dirt.
I General User Manual 23
To inate an inner tube with a Sclaverand or road valve,
proceed as follows:
18 Repairing a puncture
To repair a puncture, you will need the following equipment:
• Plastic tyre lever
• Patches
• Rubber solution
• Sandpaper
• Spare inner tube, if required
› Unscrew the valve cap anticlockwise with your
ngers.
› Unscrew the knurled nut anticlockwise.
› Push the knurled nut with your nger briey into
the valve until air escapes.
› Inate the inner tube using a suitable tyre pump.
› Screw the knurled nut back down.
› Screw the cap clockwise back onto the valve.
Ask a specialist cycle shop for advice on which tyre
pump is suitable for your valve.
To inate an inner tube with a Dunlop/Woods valve or
Schrader/car valve proceed as follows:
• Spare valve, if required
• Open-ended spanner (if your bike is not equipped
with a quick-release device)
• Tyre pump
We recommend you remove the defective wheel rst. Open
or remove the brake beforehand. The procedure for this
depends on the type of bike brake that is installed.
Read the chapter on brakes before removing the brake
as otherwise you could damage the brake system and
this could lead to accidents.
18.1 Opening the brake
› Unscrew the valve cap anticlockwise.
› Inate the inner tube using a suitable tyre pump.
› Screw the cap clockwise back onto the valve.
24 I General User Manual
18.1.1 Opening the cantilever or V-brake
› Grip the wheel with one hand.
› Squeeze the brake pads or brake arms against the
rim.
› Detach the brake cable at one of the brake arms.
18.1.2 Removing the hydraulic rim brake
› If quick-release brake mechanisms are tted, re-
move a brake unit (see ➠
the quick-release device").
› If no quick-release brake mechanisms are tted,
deate the tyre.
Chapter 9.2.2 "Operating
CJ-8S20
JAPAN
LOCK
18.1.3 Opening the side-pull calliper brake
18.2.2 Removing the rear wheel
› Open the quick-release lever on the brake arm or
brake lever.
› If no quick-release brake mechanisms are tted,
deate the tyre. The wheel can now be pulled out
between the brake pads.
18.1.4 Releasing the hub gears, roller, drum
or back-pedal brakes
› Undo the cable clamping screw or quick-release
device on the brake arm.
› With back-pedal brakes, the screw connection of
the brake arm on the chain stay must be released.
18.2 Removing the wheel
Please note that the work steps described here are for a
specic example.
Please observe the information by the relevant manufacturer or consult your specialist cycle shop.
› If your bike is equipped with derailleur gears, shi
down to the smallest sprocket. The rear derailleur
does not prevent the wheel om being removed in
this position.
› If quick-release devices are tted to your bike,
open them (see ➠
Chapter 9.2.2 "Operating the
quick-release device").
› If axle nuts are tted to your bike, release these
by turning them anticlockwise using a suitable
spanner.
› Fold the rear derailleur backwards slightly.
› Li the bike up slightly.
› Pull the wheel out of the ame.
› If the rear wheel still does not come out, open the
quick-release device rther by turning the lock nut
anticlockwise.
› Strike the wheel om above gently with the palm
of your hand to shi it.
› The wheel should drop out.
18.2.1 Removing the ont wheel
› If quick-release devices are tted to your bike,
open them (see ➠
quick-release device").
› If axle nuts are tted to your bike, release these
by turning them anticlockwise using a suitable
spanner.
› If the dropouts are specially formed to prevent the
ont wheel om falling out, continue loosening
the nuts by turning them anticlockwise. Once the
washers and nuts are clear of the dropouts, pull the
ont wheel out of the fork.
› If your bike is equipped with metal wheel locking
devices, continue loosening the nuts by turning
them anticlockwise.
› Pull the metal locking devices apart until they are
clear of the dropout.
› Now pull the ont wheel out of the fork.
Chapter 9.2.2 "Operating the
The example here shows the removal of a Shimano hub gear:
Disconnect the shiing cable to remove the rear wheel
› Disconnect the cable om the cassette joint to
remove the rear wheel om the ame
Cassette joint
› 1. Set the Revo-shi lever to 1.
Set to 1
I General User Manual 25
› 2. Pull the outer casing out om the outer casing
holder of the cassette joint, and then remove the
inner cable om the slit in the bracket.
Bracket
Outer casing holder
CJ-8S20
JAPAN
1
Slit
2
1 Pull out om outer casing holder
2 Remove om the slit
› 3. Remove the inner cable xing bolt unit om the
cassette joint pulley.
Inner cable xing bolt unit
Cassette joint pulley
LOCK
CJ-8S20
JAPAN
› 5. Undo the wheel nuts and put them to one side.
Remove the lock washers om the wheel axle.
› 6. Pull the rear wheel out of the dropout slits.
18.3 Removing the tyre and inner tube
› Unscrew the valve cap, fastening nut and the cap
nut (if installed) om the valve. Remove the valve
insert om Dunlop or Woods valves.
› Allow the remaining air to escape om the inner
tube.
› Place the tyre lever on the inner edge of the tyre
opposite the valve.
› Lever the tyre sidewall over the rim ange.
› Push the second tyre lever between the rim and
tyre approx. 10 cm away om the rst one.
› Continue levering the tyre o the rim until the tyre
has detached round the entire circumference.
› Take the inner tube out of the tyre.
If it is dicult to pull the outer casing out om the
outer casing holder of the cassette joint, insert a
2mm Allen key or # 14 spoke into the hole in the
cassette joint pulley, and then turn the pulley to
loosen the inner cable. Then remove the inner cable xing bolt unit om the pulley rst, and aer
this remove the outer casing om the outer casing
holder.
2
Remove the inner
cable xing bolt unit
1
Turn the
pulley
Pulley hole
2 mm Allen key
or # 14 spoke
3
Pull out om
the outer casing
holder
LOCK
CJ-8S20
JAPAN
18.4 Mending the inner tube
› Pump up the inner tube.
› Put the inner tube in a container lled with water
to locate the puncture.
› Push the inner tube below the surface of the water.
Air bubbles will be visible at the point where the
inner tube is torn or perforated.
› If you start losing air om the tyre on the road and
cannot nd the hole, simply inate the inner tube
hard. The hole will then get bigger as the air will
escape with greater force and you will be able to
hear more easily where it is coming om.
› Allow the inner tube to dry.
› Carelly roughen the inner tube in the area around
the puncture using the sandpaper.
› Coat this area with rubber solution.
› Wait for several minutes until the rubber solution
is touch dry.
› Press the rubber patch rmly onto the damaged
area.
› 4. Undo the screw of the brake arm and remove it.
26 I General User Manual
› Leave the rubber patch to dry for several minutes.
CJ-NX10
JAPAN
18.5 Fitting the tyre and inner tube
Make sure that foreign bodies do not enter the inside
of the tyre. Make sure that the inner tube is creaseee and not pinched at all times. When tting the
tyre, bear in mind the running direction. If the tyre
has a running direction, this will be indicated on the
tyre sidewall.
18.6 Fitting the wheel
Please note that the work steps described here are for a
specic example.
Please observe the information om the relevant manufacturer or consult your specialist cycle shop.
18.6.1 Inserting the ont wheel
› Make sure that the rim tape covers the spoke nip-
ples and is undamaged.
› Put the rim with one edge inside the tyre.
› Push one side of the tyre completely into the rim.
› Insert the valve through the valve hole in the rim
and t the inner tube inside the tyre.
› Push the tyre over the rim sidewall.
› Pull the tyre forcelly into the centre of the rim.
The area that has already been tted will slip into
the base of the rim.
› Check once again that the inner tube is seated
correctly.
› Push the other side of the tyre completely over the
rim ange using the heel of your hand.
› With Dunlop or Woods valves: Put the valve insert
back into position and screw the cap nut tight.
› Inate the inner tube slightly.
› Check that the tyre is correctly seated and is true
using the indicator ring on the rim sidewall. Adjust
the seating of the tyre by hand if it does not run
straight.
Bear the running direction of the tyre in mind when
tting the ont wheel.
If your bike is equipped with a disc brake, make sure
that the brake discs are correctly positioned between
the brake pads.
18.6.2 Inserting the rear wheel
18.6.2.1 Bikes with derailleur gears
› If your bike is equipped with derailleur gears, put
the chain back onto the smallest sprocket when
tting the rear wheel.
› Insert the wheel as far as it will go so it sits cen-
trally in the dropouts.
› Tighten the hub nut, or rmly close the quick-
release device (see ➠
quick-release device").
Chapter 9.2.2 "Operating the
› Inate the inner tube up to the recommended tyre
18.6.2.2 Bikes with hub gears
pressure.
Fitting a wheel with gear hub in the ame
› 1. Fit the chain on the sprocket and oer up the
hub axle to the dropouts.
Hub axle
Dropout
I General User Manual 27
› 2. Fit the xing washers onto both sides of the hub
CJ-NX10
JAPAN
LOCK
7R
CJ-NX10
JAPAN
LOCK
7
R
axle. Turn the shiing arm until the projections on
the xing washers engage with the slits in the
dropouts. In this case the shiing arm can be
mounted more or less parallel to the ame fork.
Locking washer (le-hand side)
Shiing arm
Dropout
Counter the clamp nut with a 10 mm spanner when
tightening the clamp screw for assembly of the brake
arm clamp.
Tightening torque
2
– 3Nm
Locking washer
(right-hand side)
Frame fork
› The projecting part must be on the dropout side.
› Fit the xing washers so the projections precisely
engage in the slits in the dropouts on the ont or
rear of the hub axle.
› 3. Take up the slack in the chain and fasten the
wheel onto the ame with the cap nuts.
Tightening torque
30 – 45 Nm
Cap nut
Locking washer
› 4. Fit the brake arm with brake arm clamp correctly
onto the ame fork.
Clamp nut
Brake arm
Clamp screw
Once you have installed the brake arm clamp, make
sure the clamp screw projects roughly 2 to 3mm beyond the clamp nut.
Brake arm
Clamp nut
2 – 3 mm
Brake arm clamp
Clamp screw
(M6 × 16mm)
› 5. Before using the back-pedal brake, make sure
the brake is working properly and the wheel turns
easily.
Tighten all screws to the prescribed torque as otherwise screws could shear o and components could
come loose or detach altogether (see ➠
Chapter 30.3
"Tightening torques for screw connections").
28 I General User Manual
› Thread in the brake cable and secure it or close the
Brake arm clamp
Frame fork
quick-release brake mechanism.
› Check that the brake pads make contact with the
brake contact surfaces.
› Check that the brake arm is securely fastened.
› Test the brakes.
Installing the shiing cable with hub gears
CJ-8S20
JAPAN
LOCK
› Bring the cable around to the cassette joint pulley,
hold so that the inner cable xing nut is facing to
the outside (toward the dropout), and then slide
the ats part of the inner cable xing washer into
the gap in the pulley.
Flats part of the inner
cable xing washer
Gap in pulleyInner cable
xing nut
Pulley
› Attach the inner cable to the pulley as shown in the
illustration, pass the inner cable through the slit in
the cassette joint bracket, and then insert the end
of the outer casing securely into the outer casing
holder.
LOCK
CJ-8S20
JAPAN
Inner cable
Pulley
Bracket
Bracket
Outer casing holder
CJ-8S20
JAPAN
› Turn the cable 60° anticlockwise and attach it on
the hook.
Hook
LOCK
CJ-8S20
Turn the
JAPAN
cable 60°
2
Slit
1
1 Pass through the slit
2 Insert into the outer casing holder
› If rst inserting the outer casing into the outer
casing holder is easier, then rst insert the outer
casing into the outer casing holder, and the insert a
2mm Allen key or a # 14 spoke into the hole in the
cassette joint pulley, and then turn the pulley so
that the inner cable xing bolt unit ts into the gap
in the pulley.
1
3
LOCK
CJ-8S20
JAPAN
2
Hole in pulley
2 mm Allen key
or # 14 spoke
1 Insert into the outer casing holder
2 Turn the pulley
3 Insert the inner cable xing bolt unit
I General User Manual 29
Check that the inner cable is correctly seated inside
the pulley guide.
Guide OK
LOCK
CJ-8S20
JAPAN
LOCK
Guide not OK
CJ-8S20
JAPAN
19 Bike gears
19.1 Derailleur gears
This User Manual describes the handling of typical, commercially available gear-shi components for MTB, ATB,
cross and road bikes. Separate instructions are provided
for other components on the CD or on the web pages of the
relevant manufacturer in the Internet. If you have questions on installation, adjustment, maintenance and operation, please consult a specialist cycle shop.
If gear-shi components are loose, worn, damaged or
adjusted incorrectly, this poses a risk of injury to the
rider. Have the derailleur gears adjusted at a professional bike workshop.
• Always contact your specialist cycle shop if the
chain jumps o the chainrings or sprockets when
riding or
• you hear unusual noises or
• you cannot change gears easily or
• the rear derailleur, ont derailleur or other
gear-shi components are loose, damaged or
distorted or
• chain links are defective or worn.
30 I General User Manual
19.1.1 Operating the shiing lever
The bike chain must not be on the smallest chainring
at the ont and the small outer rear sprocket wheel
simultaneously. The bike chain must not be on the
largest chainring at the ont and large inner sprocket
wheel at the rear simultaneously. Otherwise the bike
chain could jump o.
Never pedal backwards when changing gears as you
could damage the gear-shi mechanism.
Only make changes to the gear-shi system carelly
and in small increments. If settings are made incorrectly, the bike chain could jump o the sprocket
wheel and cause you to fall o the bike. If you are
unsure about what to do, have this work carried out
by a professional bike workshop.
Even if the gear system is perfectly adjusted, it can
produce noise if the chain is running at an extremely
sharp angle. This does not mean it is defective and
does not damage the drive. As soon as the chain is at
a more shallow angle, the noise will disappear.
19.1.1.1 Shiing lever on road bike
Shimano shiing lever
Lever b
om large to
small chainring
a
Lever
a
Lever
a
Lever a: Shi to a larger chainring
Lever b: Shi to a smaller chainring
Lever
om small to
large chainring
Lever
b
Lever b
om large to
small chainring
a
Lever
om small to
large chainring
Once released, all levers revert to their initial position.
Never ride without a spoke protector. If a spoke protector is not installed, you must have one retrotted.
Otherwise the bike chain or rear derailleur could land
in the gap between the sprocket and the spokes.
You should therefore select the lowest gear (largest
sprocket wheel) via the gear-shi handle for the rear
derailleur carelly as otherwise the rear derailleur
could collide with the spokes and damage them.
I General User Manual 31
Operating the rear derailleur shiing lever
Lever a: Shi to a larger sprocket.
Lever a engages in positions 1, 2 and 3.
Lever
a
Starting position of lever
a
1. Shiing up one gear to
next larger sprocket.
Example: shiing om
3rd to 4th gear
2. Shiing up two gears
to a larger sprocket.
Example: shiing om
3rd to 5th gear
1. Click-in position
3. Click-in position
2. Click-in position
When lever a is pressed, lever b moves with it. However, you should avoid putting any pressure on lever b
in doing so. The same applies for lever a when pressing lever b. The gear will not change if both levers are
operated at the same time.
Operating the ont derailleur lever (standard)
Lever a: Shi to a larger chainring
Lever
a
Gear shi complete stroke
Starting position
of lever
a
Actual pull
3. Shiing up three gears
to a larger sprocket.
Example: shiing om
3rd to 6th gear
Lever b: Shi to a smaller sprocket. Press lever b once to
change to the next sprocket down (smaller).
Lever
b
1. Shiing up one gear to
next smaller sprocket.
Example: shiing om
4th to 3rd gear
Starting position
of lever
b
If the lever movement does not eect a ll changeover of chainring,
press the lever repeatedly by the amount (X') to move the lever the
remaining distance (X) and change gears.
Lever
b
Gear shi complete
stroke
Click-in position
Click-in position
Lever b: Shi om intermediate chainring to smallest chainring
Starting position
of lever
b
When lever a is pressed, lever b moves with it. However,
you should avoid putting any pressure on lever b in doing
so. The same applies for lever a when pressing lever b.
The gear will not change if both levers are operated at the
same time.
32 I General User Manual
Operating the ont derailleur lever with trimming
(noise prevention), optional
Gear shiing operations
Lever a: Shi to a larger chainring
Lever
a
Gear shi complete stroke
If the lever movement does not eect a ll changeover of chainring,
press the lever repeatedly by the amount (X') to move the lever the
remaining distance (X) and change gears.
Starting position
of lever
a
Actual pull
Trimming (noise prevention)
Depending on the position of the chain aer shiing, it
may rub against the outer chain guide plate or inner chain
guide plate of the ont derailleur and produce noise. In
this case, lightly press lever a or lever b to move the ont
derailleur until it is no longer in contact with the chain.
This procedure is known as "trimming". Trimming is possible if the chain is on the large, intermediate or small
chainring.
If you perform the trimming operation at one of the following positions, the noises will disappear completely.
Lever b: Shi om intermediate chainring to smallest
chainring
Lever
b
Gear shi complete
stroke
Click-in position
Click-in position
When lever b is operated, there is one click where trimming (the
noise prevention mechanism) enagages, and a second stronger click
when the gear shi stroke is completed. Aer trimming, the next
push will complete the gear shi stroke.
Starting position
of lever
b
I General User Manual 33
CHAIN POSITION INDICATION
large chainring
smaller
sprockets
Middle chainring
Smaller
sprockets
Small chainring
Chain in contact with
outer chain guide plate
Outer
chain guide plate
Chain
TRIMMING
LEVER OPERATION FRONT DERAILLEUR MOVEMENT
a
Lever
Trimming
before trimming aer trimming
Front derailleur movement
Click-in
position
(contact)
Smaller
sprockets
Large chainring
Larger
sprockets
Middle chainring
Larger
sprockets
Small chainring
Chain in contact with inner chain guide plate
b
Lever
Inner
chain guide plate
Trimming
before trimming aer trimming
Front derailleur movement
Click-in
position
Chain
(contact)
Larger
sprockets
34 I General User Manual
SRAM shiing lever
Setting the swivel range
The range of the shiing and brake lever pivoting movement can be adjusted individually to suit the size of your
hand.
0° X°
Click
XX°
Click
Click
Click
0
Rear shiing lever: To shi to a tougher (higher) gear,
press the small shiing lever gently inwards until you hear
or feel a click. To shi to an easier (lower) gear, press the
small shiing lever rther inwards until you hear or feel
a second click. You can shi down by up to three gears at
once.
Front shiing lever: Press the small shiing lever inwards
as far as it will go to shi om the small chain wheel to
the large chain wheel. To shi om the large chain wheel
down to the small chain wheel, press the small shiing
lever in the centre until you hear or feel a distinctive click.
› First, set the shiing lever range then adjust the
brake lever until the brake lever limit stop makes
contact with the shiing lever. This ensures that
the brake lever cannot strike the shiing lever
when it springs back.
› To adjust the range of the shiing lever, push it
inwards to reach the range adjustment screw.
Push the adjustment screw inwards using a mandrel or your ngernail and turn it anticlockwise
to move the shiing lever closer to the handlebars.
19.1.1.2 Shiing lever on MTB, trekking and touring bike
Standard shiing lever
Both levers a and b always revert to the initial position
aer they are pressed. The crank must always be turned
when a lever is pressed.
To prevent chain rubbing in extreme positions, the
shiing lever at the ont has a trimming nction for
the ont derailleur. You can use this if the chain is on
the large chain wheel.
To shi the ont derailleur to the trim position, press
the small shiing lever gently inwards until you hear
or feel a gentle click.
Operating the ont derailleur shiing lever
Lever a starting position
Shiing om a small to a large chainring
Press lever a once to move the chain om a small to a
larger chainring.
I General User Manual 35
Zunehmende
Pedalkraft
Zunehmende
Pedalkraft
Abnehmende
Pedalkraft
Abnehmende
Pedalkraft
b
Lever
Shiing om a large to a smaller chainring
Press lever b once to move the chain om a large to a
smaller chainring.
Operating the standard rear derailleur shiing lever
Lever a starting position
1
Gear shi complete
stroke
Click-in position
Trimming operation
Click-in position
b
Lever
When lever b is operated, there is one click where trimming (the noise prevention mechanism) engages, and a
second stronger click when the gear shi stroke is complete. The noise prevention mechanism no longer clicks
once the trimming operation is complete which means
that only the click-in positions will be heard when shiing
between sprockets.
2
Shiing om a small to a larger sprocket
To shi by one gear only, push lever a to position 1. To
shi by two gears, push the shiing lever to position 2.
You can shi a maximum of 3 gears using this method.
Chain position
Front derailleur movement
If the chain is on the large chainring and the large sprocket, the chain will rub the ont derailleur producing a characteristic noise. When this happens, press lever b lightly
to the point where it clicks, this causes the ont derailleur
to move slightly towards the smaller chainring, thereby
eliminating the noise.
Twist-grip shiers
To shi up or down one gear only, turn the twist-grip shier by one increment forwards or backwards.
b
Lever
Shiing om a large to a smaller sprocket
Push once to shi to a smaller sprocket.
36 I General User Manual
increasing
pedal force
reducing pedal force
reducing pedal
force
increasing pedal force
If you wish to shi up or down several gears at once, continue turning the shiing lever by the required number of
shi positions and in the required direction.
Rear derailleur
The adjustment screw may also be on the shiing
lever or on the ame.
Have your specialist cycle shop carry out maintenance
on the derailleur gears, or replace or adjust them.
Precision adjustment / rear derailleur
Operate the shiing lever to shi the chain om the smallest sprocket to the second sprocket. Then take up the
slack in the shiing cable with the shiing lever and turn
the crank.
If the chain
jumps to the third
sprocket:
Adjustment
screw
› Turn the adjustment screw clockwise until the
chain moves back onto the second sprocket.
If noises cannot
be heard:
Adjustment screw
B
A
Cable housing adjustment screw
Optimum adjustment
Once the slack in the shiing cable
has been taken up by the shiing
lever, the chain should ideally rub
the third sprocket and produce a
noise.
Release the shiing lever in second
gear and turn the crank.
If the chain rubs the third sprocket, turn the adjustment
screw clockwise slightly until the grinding noise stops.
To ensure problem-ee SIS operation, you will need to
lubricate all power-transmitting parts.
Adjustment
screw
› Turn the screw anticlockwise until the chain rubs
against the third sprocket.
If the chain is in the position shown, it could rub
against the chainrings or the ont derailleur and
make a noise. If this is the case, you can shi the
chain onto the second or next largest sprocket.
Chainrings
Sprockets
I General User Manual 37
Cleaning
› Whenever possible, avoid using cleaning agents on
the chain. If you use cleaning agents, such as rust
remover, this may wash lubricant out of the chain
which could lead to malnctions.
› The chainrings and sprockets should be cleaned
regularly using a neutral cleaning agent.
› You should clean the derailleur and lubricate the
moving parts (mechanism and rollers) at regular
intervals.
19.2 Hub gears
This User Manual describes the handling of typical, commercially available gear-shi components of a gear hub on
a city or trekking bike. For other components, refer to the
separate information or enclosed instructions.
If you have questions on installation, adjustment, maintenance and operation, please consult a specialist cycle
shop.
The gears can be changed when the pedals are turning. Very occasionally, the hub may produce a harmless noise which is caused by its internal cogs and
stop notches.
If you encounter resistance when turning the wheel,
the brake pads will need to be replaced or the hub
will need to be lubricated. This should be done by a
professional bike workshop.
If the chain jumps o the the sprockets when you are
riding, the slack in the chain must be taken up immediately. If there is no rther scope for adjustment, the
sprockets and chain must be replaced.
19.2.1 Operating the hub gears
19.2.1.1 Shimano 7/8-speed shi lever
› Turn the twist-shi lever to select all 8 (7) gears.
If the hub is mounted on the ame, the correct xing washers must be used on both sides and the hub
nuts must be tightened to the prescribed torque (see
➠
Chapter 30 "Technical data").
If the xing washers are used on one side only or the
hub nuts are tightened incorrectly, the hub may malnction: It could rotate. This could cause the shiing
cable to pull the handlebar to one side and cause a
serious accident.
• Increasing pedal force (increasing resistance)
➞ indicator towards 8 (7)
Display
Revo-shi lever
• Decreasing pedal force (decreasing resistance)
Indicator
➞ indicator towards 1
These instructions on operation of the Shimano twist-shi
grips also apply for other makes of twist-shi grips.
38 I General User Manual
19.2.2 Adjusting gears with Shimano hub
gears
Example shown is a 7/8-speed hub.
› Select shi lever position 4.
› Check whether the yellow marking lines on the
bracket and cassette joint pulley line up.
yellow marking lines
select position 4
J
A
P
A
N
CJ-8
S20
CK
LO
› Turn the cable adjustment bolt on the shi lever to
align the marking lines. Next, set the Revo-shi
lever om position 4 to position 1 then back to
position 4. Check that the yellow marking lines still
line up.
Cable adjustment bolt
Yellow marking lines appear at two points on the cassette
joint. Use the line which is most clearly visible.
Bike in normal position
line up markings
Cassette joint
pulley
LOCK
CJ-8S20
JAPAN
Bracket
Bike in inverted position
line up markings
Cassette joint
JAPAN
CJ-8S20
LOCK
pulley
Bracket
I General User Manual 39
20 Bike chain
There are two types of bike chain:
• A wide bike chain (½ × 1 / 8") for hub gears and
• A narrow bike chain for derailleur gears. These are
available in dierent widths, depending on how
may sprockets are on the cassette. Only use chains
that are approved for precisely the number of
sprocket wheels on your bike.
› Clean and lubricate your bike chain regularly.
› To prevent premature wear of the bike chain when
using derailleur gears, select gears that keep the
chain skew as marginal as possible.
To check the wear in the bike chain, proceed as follows:
› Take the section of the chain that rests on the ont
chainring between your thumb and forenger.
› Pull the bike chain o the chainring. If the bike
chain can be lied by a signicant amount, it is
worn and must be replaced by a new one.
Tighten all screws to the prescribed torque as otherwise screws could shear o and components could
come loose or detach altogether (see ➠
"Technical data").
Chapter 30
20.1 Maintenance of bike chains
Bike chains are wear parts. Bike chains with hub gears
wear out aer roughly 3000km, and aer roughly
2000km with derailleur gears.
If the bike chain is worn, it can break and cause a
crash. If your bike chain is worn, have it replaced by
your specialist cycle shop before using the bike again.
› With hub gears, the chain tension must be adjusted
so that vertical play of one to two centimetres is
present in the unsupported chain span between the
chainring and sprocket wheel.
To take up the slack in the bike chain, proceed as follows:
› Loosen the rear wheel nuts.
› Pull the wheel back into the dropouts until only the
permissible amount of play is present in the bike
chain.
› Tighten all screw connections carelly clockwise.
40 I General User Manual
21 Brake, brake levers and brake
systems
This User Manual describes the maintenance and handling
of typical, commercially available brake components for
MTB, ATB, cross and road bikes. For other components,
refer to the separate information or enclosed instructions.
If you have questions on installation, adjustment, maintenance and operation, please consult a specialist cycle
shop.
21.1 Important information and
precautionary measures
Rubber brake blocks and brake pads must not come into
contact with oil or grease. If the rubber brake blocks and
brake pads come into contact with oil or grease, this drastically reduces their braking performance and they must
be replaced.
Tighten all screws to the prescribed torque as otherwise screws could shear o and components could
come loose or detach altogether (see ➠
"Technical data").
Chapter 30
"Bicycles must be equipped with 2 brakes that operate independently of one another."
Paragraph 65 of the German Road Trac Licensing
Regulation (StVZO), similar rules apply in all other EU
countries.
Have maintenance work on the brakes carried out by a
professional bike workshop.
Do not allow uids containing oils to come into contact with the brake pads, brake contact surfaces on
the rim, brake blocks or brake disc as this could otherwise impair the eectiveness of the brake.
Brake blocks and brake pads are wear parts. Check the
wear condition of these parts regularly. This can be identied by a marking. On the brake block, for example, the
grooves will no longer be visible. Always replace both
brake blocks at the same time.
Use genuine spare parts only as otherwise you could impair the nctions of the bike or damage it.
To obtain correct iction pairing, only use brake pads that
are suitable for the rim as otherwise the braking distance
would be extended and wear increased. With carbon rims
in particular, only brake pads that are expressly intended
for this purpose should be used.
Brake cables are wear parts. You should check the
wear condition of the brake cables regularly and replace these if necessary.
Check the brake cable for rust and aying and replace
the cable if it is faulty. If you do not, the brakes could
malnction.
There are dierent types of brakes, the type of brake depends on what it is used for:
• hub brakes,
• disc brakes and
• rim brakes.
The brakes can be operated mechanically or hydraulically.
With hub gears, the brake lever that operates the ont
wheel brake is normally on the right-hand side, and
with derailleur gears it is on the le. Remind yourself
of the position of the brake lever before you ride o.
If you wish to attach the brake lever on the opposite
side of the handlebar, follow the manufacturer's user
manual or ask your specialist cycle shop to do this.
I General User Manual 41
21.2 Brake lever
21.2.1 Standard brake lever
The bike is equipped as standard with a suitable brake
lever. Check regularly that when you operate the brake
lever it does not reach the handlebar and make contact
with it. With the brake lever pulled, push the bike forward
and check whether the braking performance is sucient.
If the bike rolls slightly forwards, you will need to have
the brake cable readjusted or the brake pads replaced.
Brake cable adjustment screw
Lever pull range
adjustment screw
Fastening screw
21.3.1 Drum and roller brakes
With the roller brake or drum brake, the braking force is
transmitted via a cable om the hand brake lever to the
brake system. If applied continuously for an extended
period, roller brakes or drum brakes become very hot.
This reduces the braking performance and can result in
complete failure of the brake. You should adapt your handling accordingly.
The brake lever of roller and drum brakes requires
special tuning.
› Check regularly that the screws on the brake lever
are tight.
› Turn them clockwise to retighten if necessary. For
the correct tightening torque, refer to ➠
"Technical data".
Chapter 30
21.3 Hub brakes
Hub brakes are virtually maintenance-ee as the brake
block is inside the hub.
If applied continuously for an extended period, hub
brakes become very hot. This reduces the braking
performance and ultimately complete failure of the
brake. You should adapt your handling accordingly.
› Pull on the ont wheel or rear wheel hand brake
lever with the same amount of force as you would
apply when braking sharply during a ride. Then
push the bike forwards. The rear wheel should lock.
The ont wheel should decelerate so rapidly that
the bike starts to tip forwards.
› Lubricate the cable-pull regularly.
Brake pads are wear parts. Have the brake pads for
back-pedal, roller and drum brakes checked regularly,
and replaced if necessary, by a professional bike
workshop.
If you have not used your bike for a while, there may
be surface rust in the brake drum which can increase
the braking force. You should therefore brake gently
several times when riding o to remove the surface
rust. This prevents sudden blocking of the brake.
42 I General User Manual
21.3.2 Back-pedal brake
Avoid operating the back-pedal brake continuously on
long descents as the internal components of the brake
system can become extremely hot which reduces braking performance. On long steep descents, always alternate between the rear wheel brake and the second
brake (ont wheel brake) to allow the rear wheel
brake to cool down. As the brake drum can become
extremely hot when braking for prolonged periods,
you should not touch it for at least 30 minutes aer
riding.
Brake drum
With back-pedal brakes the braking force is transmitted
by the foot via the chain to the brake system. If applied
continuously for an extended period, back-pedal brakes
become very hot. This reduces the braking performance
and can result in complete failure of the brake. You should
adapt your handling accordingly.
The back-pedal brake is operated by pedalling backwards. The force applied by the back-pedal brake
varies depending on the position of your feet/pedals.
If the crank arms are vertical, i.e. one of your feet is
in the highest position and the other is in the lowest
position, you cannot brake hard. Move the crank arms
into a horizontal position if you think you may want/
have to brake.
The back-pedal brake is easy to apply in a controlled
manner. The maximum braking performance is only
reached aer a certain run-in period.
Operate the back-pedal brake carelly to familiarise
yourself with it and get a feel for its retarding eect.
If you have not used your bike for a while, there may
be surface rust in the brake drum which can increase
the braking force. If you have not used your bike for
some time, you should brake gently several times
when riding o to remove the surface rust. This prevents sudden blocking of the brake.
If excessive overheating of the hub occurs, this can
lead to loss of lubricant and a sharper braking eect.
In these cases, have the brake checked by a professional bike workshop.
I General User Manual 43
21.4 Rim brakes
V-brakes produce an extremely high braking force.
You should therefore familiarise yourself with the
V-brake and only apply the brake gradually. Practise
emergency braking until you are sure you will be able
to remain lly in control of your bike if you have to
apply the brakes with force.
If additional suspension elements in the brake system
(power modulators) are used improperly, this can lead
to serious accidents. The required spring strength of the
power modulator depends on the gross weight of the bike.
If the brake blocks are so worn that you can no longer see
notches, have them replaced by a professional bike workshop.
21.4.2 Adjusting the brake-pad clearance in
relation to the rim
Turn the cable adjustment bolt to adjust the clearance
between the brake pad and the rim. Turn the bolt inwards
(clockwise) to increase the brake-pad clearance. Turn the
bolt outwards (anticlockwise) to reduce the brake-pad
clearance. The clearance between the brake blocks and
rim should be roughly 1mm.
Adjusting the cable-pull
Cable adjustment bolt
With V-brakes
21.4.1 Readjusting the brake
The brakes on your bike are set correctly at the factory or
by your cycle dealer. The gap between the brake block and
the rim is roughly 1 – 1.5mm. However, as the brake blocks
wear down the gap steadily increases and the brake lever
must travel a greater distance to achieve the same braking
eect. You should therefore inspect the brake at regular
intervals and adjust it if the brake lever travel distance is
too great or the brake is not working properly.
Check the brake as follows:
› Pull the ont wheel and then the rear wheel hand
brake lever with the same amount of force as you
would apply when braking sharply during a ride.
Then push the bike forwards.
› The rear wheel should lock and
› the ont wheel should decelerate so rapidly that
the bike starts to tip forwards.
Cable adjustment bolt
With side pull brakes
44 I General User Manual
21.4.3 Wear of brake pad
Most brake pads for rim brakes come with grooves or
notches.
New brake pad
If these grooves are worn and can no longer be seen, this
is normally a sign that the brake pad is worn.
If required, you can readjust the rebound force via the
spring adjustment screw so that both brake arms move
symmetrically. Once you have done this, check that the
brake is working properly (see ➠
ing the brake").
If the brake is still not working properly, or the brake
pad is so worn that it is not possible to readjust it,
have your bike checked at a professional bike workshop and replace the brake block.
Chapter 21.4.1 "Readjust-
21.5 Disc brakes
Worn brake pad
Do not ride your bike if the brake pads are worn.
Have them replaced by a professional bike workshop
instead.
2
1
2
1
2
1
Disc brake
With this brake type, the brake discs are on the hub and
the brake calliper is on the ame or fork.
Have your disc brakes adjusted by a specialist cycle
shop. If this is done incorrectly, an accident may occur.
Once the brakes have been adjusted, always perform a
brake test by pushing the bike quickly forwards and operating the brake lever. You should only use your bike if you
can safely stop it using the brakes.
Spring adjustment
screw
1 mm 1 mm
Spring adjustment
screw
Disc brakes require a brake lead time during which the
braking force increases. Bear this in mind throughout the
entire brake lead time. The same eect also occurs aer
replacing the brake block or disc.
I General User Manual 45
If you hear unusual noises when braking, the brake blocks
may have reached their wear limit. Allow the brakes to
cool down then check the brake block depth. Have the
brake blocks replaced if necessary.
When installing, removing and carrying out maintenance on the wheel, do not touch the brake disc with
your ngers when it is turning. You could be seriously
injured if you catch your ngers in the cutouts of the
brake disc.
The brake calliper and the disc can become extremely
hot when braking. You should therefore not touch
these parts when riding the bike or immediately aer
dismounting as you could burn yourself. Before adjusting the brakes, check that the parts have cooled
down suciently.
If the brake disc is worn, cracked or bent it must be replaced. Have this work carried out by a professional bike
workshop.
If the depth of the brake blocks is less than 0.5mm, they
must be replaced.
> 0.5mm 0.5mm
21.5.1 Hydraulic disc brake
The hand brake lever of the hydraulic disc brake is
equipped with a master cylinder. The hydraulic uid is
fed through a tube to the brake cylinders. This actuates
the brake pistons which push the brake blocks against the
brake disc. This type of brake requires little maintenance
and can be very powerl.
You must only t a disc brake on your bike providing
suitable mounting devices are installed on the ame
and the bike fork. If in doubt, consult a specialist
cycle shop.
If the brake blocks come into contact with oil or grease,
they must be replaced. If the brake disc comes into contact with oil or grease, it must be cleaned as otherwise its
braking performance will be drastically reduced.
Check whether the quick-release lever for the wheel is
on the side opposite the brake disc. If the quick-release
lever is on the same side as the brake disc, there is a
danger you could burn yourself when operating the lever.
The heat in the brake disc could also reduce the clamping
force of the quick-release device.
Once the brakes have been adjusted, always perform
a brake test by pushing the bike quickly forwards and
operating the brake lever. You should only use your
bike if you can safely stop it using the brakes.
Check regularly, also before each journey, that the lines
and connections are tight. If lines and connections are not
tight, brake uid may escape om the brake system. The
brake may not work properly as a result.
If uid escapes om the braking system, do not use the
bike and have the necessary repair work carried out immediately by a professional bike workshop.
If you continue riding the bike in this condition, the risk
of brake failure is extremely likely.
If the brake blocks come into contact with oil or grease,
they must be replaced. If the brake disc comes into contact with oil or grease, it must be cleaned as otherwise its
braking performance will be drastically reduced.
46 I General User Manual
21.5.2 Vapour bubble formation
› Vapour bubble formation can occur if the brakes
are operated continuously for some time, e. g. during a long steep descent.
Instead of applying gentle pressure continuously
with the brakes, operate them for shorter periods,
with more force if necessary, releasing the brake
lever intermittently.
› Vapour bubbles form if water in the brake uid
heats up, evaporates and forms bubbles in the
brake system.
As these are easily compressed, the brake lever travel
distance increases.
When transporting or storing the bike upside down,
air bubbles can form in the brake system uid reservoir.
If you then use the bike, the brakes could fail and
cause a serious accident.
Once the bike is in the correct riding position, pull the
brake lever several times to check whether the brakes
respond normally.
Brake pads and brake blocks are wear parts. Have the
brake pads of hydraulic disc brakes checked regularly,
and replaced if necessary, by a professional bike
workshop.
21.5.3 Cleaning the brake system
If the brake blocks come into contact with oil or grease,
they must be replaced. If the brake disc comes into contact with oil or grease, it must be cleaned as otherwise its
braking performance will be drastically reduced.
› Clean and maintain the brake system using isopro-
pyl alcohol, soapy water or a dry cloth. Do not use
commercially available brake cleaning agents or
agents to prevent braking noises as these can damage components such as the seals.
21.5.4 Fitting/removing the wheel
› When removing the wheel, we recommend you
use a brake block spacer. This prevents the piston
om being pushed out if the brake lever is operated once the wheel has been removed. This also
prevents air bubbles in the expansion vessel om
entering the system.
If not, adjust them as follows:
› Adjust the brake lever so it is parallel to the ground
and operate it slowly several times so the bubbles
return to the reservoir.
› If the response is still poor, the brake system must
be vented. Have this work carried out by a specialist cycle shop.
› If the brake lever is operated and the brake block
spacer is not inserted, the pistons may extend rther than normal. Put the bike in an upright position to push back the brake blocks. Use a clean,
at screw driver or tyre lever and be carel not to
scratch the brake blocks. If the brake blocks are
not tted, push the piston back carelly without
damaging it. If you have trouble pushing back the
brake blocks or piston, remove the reservoir cap
and try again. Note that some oil may ow out the
reservoir.
› Aer tting the wheel, check that the quick-release
lever is on the side opposite the brake disc. If it
is on the same side as the brake disc, there is a
danger of the lever and brake disc obstructing one
another and this could also reduce the clamping
force of the quick-release device.
I General User Manual 47
22 Lighting system
In some EU countries, only lighting systems that are
prescribed by national legislation (the Road Trac Licensing Regulations (StVZO) in Germany for example)
and have been approved for use may be installed on
bikes. If in doubt, ask your specialist cycle shop.
22.1 Specications for lighting system
• At a distance of ve metres, the cone of light
thrown by the ont light must be at half the height
of its exit point. The centre of the cone of light
determines its height.
22.3 Generator / dynamo
The dynamo produces the energy required to operate the
ont and rear lights. There are dierent types of dynamos.
22.3.1 Sidewall dynamo
Sidewall dynamo
5 m
0.5 me. g. 1 m
Aligning the ont light
• The cone of light thrown by the ont light must
only light the road for ten metres at the most. The
centre of the cone of light determines its distance.
22.2 Special regulations for road bikes
• You can t battery-operated ont lights and rear
lights to sports bikes with a maximum weight
of 11 kg (road bike). Please familiarise yourself
with the applicable regulations and, if applicable, have the bike retted.
The dynamo must be positioned so its longitudinal axis
is perpendicular to the wheel axle. The roller must be in
contact with the designated traction surface on the tyre
across its entire width.
Only switch the dynamo on and o when the bike is
stationary as otherwise you could put yourself and
other road users in danger. The sidewall dynamo is
less eective in wet conditions. Provide additional
lighting if necessary.
22.3.1.1 Switching the sidewall dynamo on and o
› Switch the dynamo on/o via the pushbutton or
the lever. The traction roller is now on the tyre
sidewall.
• Always carry these with you.
• Dynamo-operated lighting systems must be used
with bikes that weight more than 11 kg. The lighting system must come with an ocial test mark.
Please familiarise yourself with the applicable
regulations and, if applicable, have the bike retted.
48 I General User Manual
› To switch the dynamo o, pull it away om the tyre
and guide it into its starting position. The dynamo
engages in the starting position.
22.3.2 Hub dynamo
The hub dynamo is inside the hub of the ont wheel. The
hub dynamo is highly ecient, and the wear is extremely
low.
Hub dynamo
There is a switch or a sensor on the back of the ont light
on some bikes with a hub dynamo. The sensor switches
the light on automatically in the twilight or when passing
through a tunnel. Other models have a switch on the handlebar that switches the lighting on and o.
22.4 Failure of the lighting system
If the lighting system fails or develops a fault when
riding in the dark this could cause a serious accident.
Have the fault repaired at a professional bike workshop before you continue your journey.
Extremely powerl (rechargeable) battery-operated bicycle and outdoor lights are available om some retail outlets. With some exceptions, use of these lights on public
roads is not permitted.
If you want to remove the ont wheel, you rst need
to remove the connecting terminal for the light cable.
When you put the ont wheel back on, turn it so that
the connecting terminal for the light cable is on the
right-hand side (facing in the direction of travel). If
the connecting terminal is on the le, the dynamo will
not be able to turn properly or the lighting system
may stop working. Ensure correct polarity of the connections.
I General User Manual 49
23 Add-on components
23.1 Pannier rack
The pannier racks on the bike satis the standard
EN 14873.
The load-carrying capacity of the pannier rack falls into
one of four possible categories: 5kg, 10kg, 18kg and
25kg.
23.1.1 Front pannier rack
The information on load-carrying capacity is embossed on
the pannier rack.
The maximum load it can handle may be higher, depending on its design. This is stated separately.
If you carry luggage, this changes the ride characteristics of your bike. It increases the braking distance
for one thing. This can lead to serious accidents.
Adapt your handling to the dierent ride characteristics. Apply the brakes in good time and bear in mind
that the bike's steering response will be more sluggish.
Only carry luggage on the pannier rack provided for
this purpose. Do not attach carriers to the seatpost.
It is not designed for this purpose. Overloading by a
carrier can lead to component breakages and serious
accidents.
Front pannier rack
Front pannier racks are attached to the ont axle or the
ont fork. They are designed to carry smaller loads than
rear pannier racks. If you carry luggage on this pannier
rack, you must familiarise yourself with the changed
steering response.
Only use suitable pannier bags.
Consult a specialised dealer.
23.1.2 Rear pannier rack
If you carry luggage on your bike, it is extremely important that you do not exceed the maximum permissible
loading (see ➠
If you t another carrier, it must comply with standard EN
14873.
The maximum permissible load must be stated on the carrier (see ➠
50 I General User Manual
Chapter 30 "Technical data").
Chapter 30 "Technical data").
Rear pannier rack
This type of luggage carrier attaches to the rear triangle of
the bike.
If you attach a rear pannier rack to a ll-suspension
ame, the proportion of unsprung weight increases
which changes the suspension behaviour. You will
therefore have to readjust your suspension / damping
accordingly.
If you carry pannier bags or other loads on the pannier racks, make sure they are securely attached.
Make sure that nothing can become caught in the
spokes and the turning wheels.
Only t child seats to rear pannier racks if suitable
xtures are provided. In doing so, be carel not to
exceed the permissible weight category.
If you notice that a wheel guard is damaged, always replace it before using the bike again.
23.2.1 Re-engaging the safety-release
mechanism
Safety mechanism released Safety mechanism engaged
A plastic clip is attached to the end of the strut.
23.2 Wheel guards / mudguards
Additional struts are mounted to hold the mudguards in
the correct position. The strut is at its ideal length if the
inner edge of the wheel guard runs more or less concentrically and parallel to the tyre.
The wheel guard cannot detach when you are riding
normally. If a foreign object lodges between the ont
wheel guard and the tyre and blocks it, the mudguard
struts immediately detach om their mountings on
the fork. This allows the mudguard to deect and the
wheel will not block.
If this happens, the struts must be securely reattached. Have a specialist cycle shop check that the
mudguard, struts and plastic mounts are still in a
serviceable condition.
› Insert this clip on the strut into the easy-clip
mount on the fork until it engages.
› Align the wheel guard so that the tyre and ont
wheel guard do not touch.
To securely reattach the safety-release mechanism,
you may need to push the strut and plastic mount
slightly together by pressing hard.
Never ride with the strut detached, it must be reattached. If this is not possible, have the strut replaced
by a professional bike workshop.
Check regularly that the struts are securely fastened in the
safety-release mechanisms.
I General User Manual 51
24 Accessories and equipment
Always install enclosed accessories according to
the instructions. Use the correct tightening torques
for screw connections (see ➠
data").
› Only use accessory parts that meet the require-
ments of the national road trac licensing
regulations (these are the Road Trac Licensing
Regulations (StVZO) in Germany for example).
› Non-approved accessory parts are not safe for
use in trac and can cause accidents. All accessories or add-on components must be compatible
with your bike
› Otherwise accidents could occur or the bike
could be damaged. Ask your specialist cycle shop
for advice.
Chapter 30 "Technical
› Never attach the child seat to the bike handle-
bars directly as it will not be possible to steer
the bike safely.
› Do not use a suspension saddle if you are car-
rying a child in a child seat behind the saddle.
The child's ngers could be crushed. The coil
springs under the seat must always be completely wrapped or covered in such a way that
it is impossible to insert ngers into the coils of
the springs.
› Always strap the child into the child seat as oth-
erwise it could fall out and be severely injured.
› Make sure that children wear a snug tting bicy-
cle helmet as otherwise a severe head injury may
result in the event of a crash.
24.1 Child seat
You can carry a child up to the age of seven years on
the child seat. The rider must be at least 16 years old
in Germany.
A child seat must not be mounted on a carbon ame
as this could damage the ame.
› Only use child seats that satis the standard
EN 14344.
› These child seats must safely support the child's
feet.
When using a child seat, this adversely aects the
handling of the bike. The additional weight can cause
the bike to sway and signicantly increases the braking distance. Adapt your handling accordingly.
Not all bikes equipped with a suspension system are suitable for transporting child seats
Check the mounting options or consult your specialist
cycle shop. If the child seat is mounted incorrectly, a serious accident may occur.
Do not exceed the maximum permissible gross weight of
the bike and the maximum load-carrying capacity of the
pannier rack (see ➠
do, this could damage the pannier rack and ame and
cause a serious accident.
Chapter 30 "Technical data"). If you
› Never leave your child sitting unattended in the
child seat when you park your bike. The bike
could fall over and severely injure the child.
52 I General User Manual
24.2 Bike stand
› Never leave your child sitting unattended in the
child seat when you park your bike. The bike
could fall over and severely injure the child.
24.4 Bike basket
The xing for the basket must not damage the handlebar or handlebar stem.
› Attach the basket so as not to cover the ont
light and ont reector.
› Never ride with the stand folded out.
24.3 Bike trailer
Not all bikes are suitable for trailers. Ask your specialist cycle shop if your bike is designed and suitable for
this.
› Only use trailers that meet the requirements
of the road trac licensing regulations in your
country (the Road Trac Licensing Regulations
(StVZO) in Germany for example). Non-approved
trailers can cause accidents.
› Trailers adversely aect the handling. Adapt your
handling accordingly as otherwise the bike trailer may tip up or detach and cause an accident.
› In doing so, be carel not to bend the brake and
shiing cables.
› Do not carry more than ve kilogrammes of lug-
gage in the basket.
› Bear in mind that the steering characteristics
change when you use a basket.
24.5 Bar ends
› Practise starting o, braking, cornering and rid-
ing on hills with an unladen trailer.
› Bear in mind that the gross weight of the bike
also includes the trailer.
› A bike trailer may increase the braking distance
considerably. Failure to observe these points
could result in an accident.
Always attach bar ends securely to the handlebars as
otherwise you could have an accident.
If a thin-walled handlebar is tted to your bike, you
may require additional accessory parts to protect the
handlebar om damage. Read the manufacturer's
instructions for use carelly.
If a carbon handlebar is tted to your bike, nd out
om your specialist cycle shop whether this handlebar is approved for use with bar ends.
I General User Manual 53
25 Bike carriers for mounting on
26 Carbon components
roof and rear of car
› Only use roof and rear-mounted bike carriers
that meet the requirements of the road trac
licensing regulations in your country (the Road
Trac Licensing Regulations (StVZO) in Germany
for example). Non-approved roof and rear-mounted bike carriers are not safe for use in trac and
can cause accidents.
› Adjust your driving to take the load on your car
roof into account. Bear in mind that your car's
overall height has changed.
The bike could come o the carrier and cause a serious accident. When transporting the bike, check regularly that it is still securely fastened.
Loose parts such as tools, luggage and tool kits, child
seats, tyre pump, etc. could detach in transit and endanger other road users. Remove all loose parts om
the bike before setting o.
Carbon is a specic material that requires special handling and care when setting up and carrying out maintenance on the bike as well as when riding and also during
transportation and storage.
26.1 Properties
Carbon parts must not be deformed, dented or bent
following an accident or crash. It is possible that bres have been destroyed or have detached although
this is not evident externally.
You should therefore inspect the carbon ame and all
other carbon components very carelly if you come o the
bike or if it falls over. If you are not absolutely sure that
the bike is still in a sound condition, have the carbon components in question checked by an expert.
26.2 Torques
› Avoid transporting the bike upside down. Only
attach the bike by the handlebar, handlebar
stem, bike saddle or seatpost if so intended
by the manufacturer of the carrier. Do not use
mountings that could damage the bike fork or
ame.
› Do not attach your bike to the roof or rear-mount-
ed carrier by its pedal cranks. Always attach
bikes by their wheels when transporting them,
unless the carrier is designed for something else,
as otherwise the ame and fork of the bike could
be damaged.
You can also nd important information on using and
tting add-on components and accessories in the
Internet on the pages of the relevant manufacturer.
➠
Chapter 29 contains a link list.
Some carbon components require lower tightening
torques than metal components. If the tightening
torques are too high, this can lead to hidden damage
that may not be visible externally. Frames or other
components can break or change to the extent that
they could fall o. You should therefore always observe the information enclosed by the manufacturer
with the component(s) or ask a specialist dealer for
advice. Use a torque wrench to ensure the right tightness is maintained.
If your bike has a carbon ame and a bottom bracket
housing for a BB30 bottom bracket please note the
following:
In this case you can t an adapter so that a bottom
bracket with conventional BSA thread can be used.
However, bear in mind
• You can only install the adapter if the ame is
completely undamaged. Repairing a defective
BB30 housing serves no purpose. If it is not
installed correctly, the bottom bracket housing
may be damaged which would render the war-
54 I General User Manual
ranty void. This kind of adapter should only be
tted by a specialist cycle shop.
• Once the adapter has been tted in the carbon
ame it cannot be removed.
Inspect the following components and areas regularly (at
least every 100km) for cracks, actures or changes in
surface appearance. Furthermore, if you come o the bike
or if it falls over, these components must always subsequently be inspected:
26.4 Carbon ame
26.3 Visual inspection
If your carbon component has pre-existing damage,
it could suddenly fail completely with potentially disastrous consequences. You should therefore inspect
your carbon ame and components thoroughly on a
regular basis.
› Look for splitting, deep scratches, holes or other
changes in the carbon surface.
› Check whether the components feel soer or
have more give in them than usual.
› Check whether individual layers (paint, nish or
bres) are aking o.
If you suspect a component is no longer sound, you
should denitely replace it before riding your bike
again. You should ideally hand over your bike to a
specialist dealer for inspection.
Front derailleur clamp area, derailleur hanger, saddle
clamp, headset spacers, bottom bracket spacers, brake
boss or disc brake mount, dropout slots, suspension
mounts on main ame and rear triangle, bearing mounts
with ll-suspension ame, transition areas around
threaded bushes for drinking bottles
Mounting of a child seat to a carbon ame is not permitted. There is a danger of the ame breaking with
serious consequences.
26.5 Carbon handlebar
Transition area at handlebar stem, handles, clamping areas of other components
If your bike falls on its handlebar, the best thing you
can do is replace it. Always have bar ends retrotted
by your specialist cycle shop.
26.6 Carbon handlebar stem
Clamping area of all screws, head tube inside and outside
If you have changed the handlebar position, bear in
mind that the stem must extensively enclose the head
tube.
I General User Manual 55
26.7 Carbon wheels
Surface wear, change of surface, e. g. due to heat produced when braking, abrasion of brake blocks, wheel hub
or their anks
If you are using a bike with carbon rims, bear in mind that
the braking behaviour of this material is much poorer than
aluminium rims.
Note that only approved brake blocks may be used.
ment of pannier racks, trailers and other xtures are not
permitted due to the risk of breakage.
26.10 Splinters
Carbon bres are extremely thin and hard. You should
therefore handle damaged carbon parts very carelly.
Individual bres may detach and stick out. If these
projecting bres come into contact with your skin,
there is a danger of them splintering o and causing
an injury.
26.8 Carbon fork
Fork blades on fork head, dropouts and clamping area of
quick-release device, fork head below fork cone, clamping
area of A-head stem on inside and outside
If you have changed the handlebar position, bear in
mind that the stem must extensively enclose the carbon section.
26.9 Carbon seatpost
Transition area between seatpost and seat tube, transition
area at head of seatpost, contact area of all screws
If other carbon parts are installed on your bike, inspect
them regularly for cracks, actures or changes in surface
appearance.
26.11 Fastening in mounting stand
Only clamp your carbon ame at the seatpost when
fastening your carbon ame in a mounting stand, as
otherwise the clamping mechanism may cause visible or
concealed damage to the ame. If your bike has a carbon
seatpost, we recommend you replace it provisionally with
an aluminium or steel seatpost when carrying out this
work.
26.12 Transportation by car
When transporting the bike on the roof rack or on a towbar cycle carrier, never attach it by its ame. Always attach the bike at the seatpost, and never at the down tube,
top tube, seat tube, fork blades, steering tube, chain stay,
cranks or seat stay.
The clamping mechanism could cause visible or concealed
damage to the ame that may aect your safety. If your
bike has a carbon seatpost, we recommend you replace it
provisionally with an aluminium or steel seatpost when
transporting it.
Retapping of the thread and bearing shells and reaming of the seat tube is not permitted.
As a basic rule, if a xture is not already provided on a
carbon ame or component for an object (e.g. threaded
inserts for bottle cage), it must not be tted. The attach-
56 I General User Manual
27 Care and maintenance of the bike
› Have defective parts replaced before you ride the
bike again.
27.1 Care
Do not allow care products or oils to come into contact with brake pads, brake discs and the rim's brake
contact surfaces. This could reduce the eectiveness
of the brake.
Do not use a powerl water jet or high-pressure
cleaner. If water under under high pressure is directed at the bike, it can enter the bearings. This can dilute the lubricant which increases iction. This leads
to rusting and irrepairable damage to the bearings.
› Touch up damaged paintwork.
Treat all parts that are susceptible to corrosion more
equently than other parts with preservatives and care
products, especially during the winter and in aggressive
environments such as coastal regions as otherwise your
bike will corrode (rust) more powerlly and quickly.
› Clean all galvanised and chrome-plated parts as
well as stainless-steel components regularly.
› Preserve these parts aer cleaning with spray wax.
Make sure that wax does not come into contact
with brake discs and rims.
› If you stop using your bike for a while, in the win-
ter for example, store it in a dry place at a constant
temperature.
› Before putting your bike into storage, inate both
tyres to the prescribed tyre pressure.
Do not clean your bike with
• acids,
• grease,
• hot oil,
• brake cleaners (apart om brake discs) or
• uids containing solvents.
These substances attack the surface of the bike and
accelerate wear.
Dispose of used lubricants, cleaning agents and care
products in an environmentally sound manner. Do not
pour these substances into the domestic waste, down
the drain or into natural water bodies or the soil.
How well the bike works and how long it lasts depends on how well you look aer it.
› Clean your bike regularly using hot water, a small
amount of cleaning agent and a sponge.
To nd out more important information on looking aer
your bike, visit the Internet pages of the relevant component manufacturer. The link list in ➠
an overview with links.
Chapter 29 provides
27.2 Wear parts
Your bike is a technical product that must be regularly
checked.
Many parts on your bike are subject to a higher degree of
wear due to their nction and depending on their use.
Have your bike checked regularly at a professional
bike workshop and have the wear parts replaced.
› You should also always take this opportunity
to check your bike for cracks, dents or material
deformation.
I General User Manual 57
27.3 Tyres
27.6 Brake discs
Due to their nction, bike tyres are subject to wear. This
depends on how the bike is used and the rider can inuence this signicantly.
› Do not brake so sharply that the wheels lock.
› Check the tyre pressure regularly. The maximum
permissible tyre pressure, and normally also the
minimum permissible pressure, can be found on
the tyre wall.
› If necessary, inate the tyre up to the specied
value. This reduces wear.
› Do not expose the tyres to things that can damage
them such as sunlight, petrol, oil, etc.
27.4 Rims in conjunction with rim brakes
Owing to the interaction of the rim brake with the rim, not
only the brake pad but also the rim is subject to nctionrelated wear. If ne cracks appear or the rim anges
deform when the tyre pressure increases, this indicates
increased wear. Wear indicators on the rim allow its wear
condition to be easily identied.
› Check the wear condition of the rim at regular in-
tervals (see ➠
Chapter 16.3 "Checking the rims").
27.5 Brake pads
The brake pads on rim, roller, drum and disc brakes are
subject to wear, the extent of which depends on how the
bike is used. If the bike is ridden in hilly regions, or used
in a sporty manner, the brake pads may need to be replaced more oen. Check the wear condition of the pads
regularly and, if necessary, have them replaced by a professional bike workshop.
Brake discs also wear out as a result of intensive braking,
or during the course of time. Find out om the manufacturer of your brakes or your specialist cycle shop about
the respective wear limits. You can have worn brake discs
replaced at a professional bike workshop.
27.7 Bike chains or toothed belts
The bike chain is subject to nction-related wear the extent of which depends on care/maintenance and how the
bike is used (mileage, rain, dirt, salt, etc.).
› To increase the service life of the bike, clean the
bike chains and toothed belts regularly and lubricate the chain.
› Have the chain replaced by a professional bike
workshop once its wear limit has been reached
(see ➠
Chapter 20 "Bike chain").
27.8 Chainrings, sprocket wheels and
jockey wheels
In bikes with derailleur gears, the sprocket wheels, chainrings and jockey wheels are subject to nction-related
wear. The extent of the wear depends on care/maintenance and how the bike is used (mileage, rain, dirt, salt,
etc.).
› To increase the service life of the bike, you should
clean and lubricate these parts regularly.
› Have them replaced by a professional bike work-
shop once their wear limit has been reached.
27.9 Lamps of lighting set
58 I General User Manual
Bulbs and other lamps are subject to nction-related wear
and therefore may need to be replaced.
› In case you need to replace damaged bulbs, always
carry spare ones with you.
27.10 Handlebar tapes and handle grips
Handlebar tapes and handle grips are subject to nctionrelated wear and therefore may need to be replaced.
27.15 Sliding bearings and bearings for
ll-suspension ames, suspension
forks or other suspension elements
› Check regularly that the handles are securely
seated.
27.11 Hydraulic oils and lubricants
The eectiveness of hydraulic oils and lubricants decreases over time. If lubricants are not replaced, this increases
the wear of the relevant components and bearings.
› Clean and relubricate all relevant components and
bearings regularly.
› Have the brake uid for disc brakes checked regu-
larly, and replaced if necessary.
27.12 Gear-shi and brake cables
› Carry out regular maintenance on all Bowden
cables.
› Have defective parts replaced at a professional
bike workshop. This may be necessary especially if
the bike is oen le outdoors and is exposed to the
eects of the weather.
The suspension components on the bike, particularly the
sliding bearings, bearings and suspension elements, must
cope with very high stresses compared to the other bearings. They are therefore subject to a high degree of wear.
› Check these parts regularly and thoroughly.
› Observe the enclosed user manual om the
manufacturer.
› Your specialist cycle shop can advise on how to
look aer these sensitive components, and also on
how to replace them if necessary.
To nd out more important information on maintenance of
wear parts, visit the Internet pages of the relevant component manufacturer. The link list in ➠
an overview with links.
Chapter 29 provides
27.13 Paint nishes
Paint nishes require regular care, this also ensures that
your bike looks good.
› Check all painted surfaces regularly for damage
and touch up immediately if required.
› Consult your specialist cycle shop for advice on
how to care for your bike's surface nishes.
27.14 Bearings
All bearings on the bike, such as the headset, wheel hubs,
pedals and bottom brackets, are subject to nction-related wear which depends on the intensity and duration of
use and how well the bike is looked aer.
› Check these parts regularly.
› Clean and lubricate them regularly.
I General User Manual 59
28 Regular inspections
› Have the following components readjusted:
As the spokes settle, the length of the brake and shiing
cables increases and the bearings will run in during the
rst kilometres on the bike, you will have to have an initial inspection carried out by your specialist cycle shop
aer the rst 200 kilometres, or aer four to six weeks.
This is also important for the acceptance of claims made
under the terms of the warranty.
› Clean your bike aer every ooad ride and check
it for damage.
› Have the initial inspection carried out.
› Inspect your bike roughly every 300 to 500km, or
every three to six months.
› During this inspection, check that all screws, nuts
and quick-release devices are securely fastened.
› Clean your bike.
› Grease moving parts (apart om brake contact
surfaces) according to instructions.
› Have paint damage and rust spots touched up.
• headset,
• gearshi,
• brakes,
• suspension elements.
aer every ride
› Check the following:
• spokes,
• rims for wear and true running,
• tyres for damage and foreign objects,
• quick-release devices,
• nction of gearshi and suspension,
• brakes, hydraulic brakes for leaks,
• lighting and
• bell.
› Apply corrosion inhibitor to bare metal parts (apart
om brake contact surfaces).
› Have inoperative or damaged parts replaced.
28.1 Inspection schedule
28.1.1 Maintenance / checks
Aer the rst 200 kilometres following purchase,
and subsequently at least once a year
› Have the following checked:
• tyres and wheels.
› Have the tightening torques of the following
checked:
• handlebar,
• pedals,
• pedal cranks,
• bike saddle,
aer 300 to 500 kilometres
› Have the following checked for wear and replaced
if necessary:
• bike chain,
• sprocket,
• sprocket wheel,
• rims and
• brake pads.
› Clean the bike chain, chainring and sprocket
wheel.
› Lubricate the chain using a suitable lubricant.
› Check that all screw connections are secure.
aer 1000 kilometres
› Have the brake hub checked and, if necessary, lu-
bricate the brake sleeve with brake sleeve grease
or replace it.
• seatpost and
• fastening screws.
60 I General User Manual
aer 3000 kilometres
29 Link list
› If necessary, the
• hubs,
• headset,
• pedals,
• shiing cables * and
• brake cables
› should be
• dismantled,
• checked,
• cleaned,
• lubricated and,
• if necessary, replaced by a professional bike
workshop.
You can obtain important information on your bike and
its components via these links. The relevant user manual
is normally provided on the manufacturer's web pages, in
addition to important tips for use and making settings.
www.rohlo.de
www.speedlier.com
www.brooksengland.com
www.paul-lange.de / produkte / shimano
www.ritcheylogic.com
www.schwalbe.de
www.srsuntour-cycling.com
www.magura.com
www.sram.com
www.dtswiss.com
* Do not apply lubricants or oils to teon-coated cable casings.
Following each ride in the rain
› Clean and lubricate the following:
• gearshi,
• brake (apart om brake contact surfaces) and
• bike chain.
Not all lubricants and care products are suitable for
your bike. Ask your specialist cycle shop which product you should use in each case. If you use unsuitable
lubricants and care products, this can damage or impair the performance of your bike.
www.llspeedahead.com
www.paul-lange.de / produkte / selle_italia
www.bike-magazin.de
www.tour-magazin.de
www.radfahren.de
www.tektro.com
www.fallbrooktech.com / nuvinci.asp
www.hebie.de
I General User Manual 61
30 Technical data
30.1 Maximum permitted gross weight
of bike
The maximum permitted gross weight of the bike comprises the weight of the bike, the weight of the rider and the
weight of the luggage. It also includes the laden weight of
a trailer.
BIKE TYPE
20" trailer 50kg
20" child's bike: 60kg
24" child's bike: 80kg
Urban bike, city / trekking 130kg max. 115kg
Urban bike, semi XXL 150kg max. 135kg
Urban bike, XXL 170kg max. 155kg
E-Bike 130kg max. 105kg
E-Bike semi XXL 150kg max. 125kg
E-Bike XXL 170kg max. 145kg
MTB (hardtail) 110kg max. 100kg
MTB (hardtail), semi XXL 140kg max. 125kg
MTB (dirt) 110kg max. 100kg
MTB (ll-suspension) 110kg max. 100kg
MAXIMUM PERMITTED
GROSS WEIGHT
WEIGHT OF RIDER:
MTB (ll-suspension), semi XXL 140kg max. 125kg
Road bike 110kg max. 100kg
Road bike, semi XXL 135kg max. 125kg
Cyclo Cross / Cyclo Cross Trekking 110kg max. 100kg
The maximum permitted gross weights of carbon ames
also apply for aluminium ames.
If other gross weights are approved, for lightweight construction components for example, this will be indicated
on the bike or component.
62 I General User Manual
30.2 Maximum permitted loading
of pannier rack
Note that the data on your pannier rack or in the manufacturer's user manual may be dierent.
Observe the minimum screw-in depth. For hard aluminium
alloys this is at least 1.4 times the screw diameter (e.g.
nominal diameter M 5 × 1.4 = 7mm).
Whenever possible, you should tighten all safety-relevant
screw connections using a torque wrench. This indicates
the tightening torque in Nm (Newton metres) in each case.
› If no values are indicated on the component, use
the tightening torques in the following table.
Maximum weight loading of ont pannier rack:
• Loading area above wheel: 10kg
• Low loading area: 18kg
Maximum weight loading of rear pannier rack:
• 20" child's bike and trailer: 10kg
• 24" child's bike: 18kg
• Touring bike, city bike, trekking bike, ATB: 25kg
30.3 Tightening torques for screw
connections
Only use a suitable tool, a torque wrench for example,
to tighten the screw connections as otherwise the
screws could shear o or break.
› If the torque has been specied by the manufac-
turer of the component, this has priority.
› Carbon parts must be mounted using a special
mounting paste.
Also note other information or markings on carbon
components regarding the recommended torques.
If you tighten screws too tightly, this could damage
the components
You should therefore always observe the prescribed
tightening torque.
I General User Manual 63
SCREW CONNECTION THREAD
TIGHTENING TORQUE NM
General
Crank arm, steel M8x1 30
Crank arm, alu M8x1 30
Pedal 9 / 16" 30
Axle nuts, ont gen. 25
Axle nuts, rear gen. 30
Stem expander bolt wedge M8 23
Stem, A-head, angle adjustment M6 10
Stem, A-head, handlebar clamping xture M5 / M6 / M7 M5: 5 / M6: 10 / M7: 14
Stem, A-head, head tube M5 / M6 / M7 M5: 5 / M6: 10 / M7: 14
Bar end, outer clamp M5 / M6 M5: 5 / M6: 10
Seatpost, clamp M8 20
Seatpost, clamp M6 10
Seatpost, saddle clamping bracket M7 / M8 M7: 14 / M8: 20
Front derailleur clamp M5 5
Brake, pad M6 10
Brake, cable clamp M6 10
Sidewall dynamo, xing M6 10
Derailleur hanger M10x1 16
Bottom bracket BSA
Disc brake calliper, Shimano, IS and PM M6 6 to 8
Disc brake calliper, AVID, IS and PM M6 8 to 10
Disc brake calliper, Magura, IS and PM M6 6
Shiing lever clamp M5 5
Brake lever clamp M5 5
V-brake, fastening screw M6 10
Road bike brake M6 10
Freewheel fastening screw n. a. 40
Cassette, lock ring n. a. 30
Handles, screw-on type M4 / M5 M4: 3 / M5: 5
Carbon Carbon ame, saddle clamp M5 / M6 5
Carbon ame, water bottle holder M5 5
according to manufacturer's instructions
Carbon ame, ont derailleur clamp M5 4
Carbon handlebar, shiing lever clamp M5 3
Carbon handlebar, brake lever clamp M5 3
Carbon handlebar, handlebar clamp M5 5
Carbon handlebar, stem clamp M5 / M6 5
Overview of torques, values apply for standard screws
64 I General User Manual
30.3.1 General tightening torques
for screw connections
The screw grade, e.g. 8.8, is embossed in the screw head.
Unless otherwise specied by the manufacturer, the following tightening torques (average values) apply depending on the screw grade:
30.5 Lighting set
Depending on which type of lighting set is tted on your
bike you may require dierent spare lamps. The following
table shows which bulbs you require.
TYPE OF LIGHTING SET USED POWER SUPPLY
GRADE
THREAD
M4 3 2.7 3.8 4.6
M5 5 5.5 8 9.5
M6 8 9.5 13 16
M8 20 23 32 39
M10 40 46 64 77
VA /
VA
. . .
30.4 Tyres and tyre pressure
The recommended tyre pressure is stated in either bar or
PSI.
The following table shows standard values converted, and
also information on which tyre widths these pressures
normally apply.
TYRE WIDTH
in mm
PSI BAR
Front light 6 V 2.4 W
Front light, halogen 6 V 2.4 W
Rear light 6 V 0.6 W
Rear light with stand light 6 V 0.6 W
Lighting with LED lights LED lights cannot be
replaced
Dynamo 6 V 3 W
Hub dynamo 6 V 3 W
25 HD* 80 – 110 5.5 – 7.6
28 HD* 70 – 80 4.8 – 5.5
28 60 4.1
32 60 – 70 4.1 – 4.8
37 50 3.5
40 60 4.1
42 60 4.1
47 40 – 50 3.5 – 4.1
57 – 62 30 – 40 2.1 – 2.8
* HD = high-pressure tyre
Note that the manufacturer's specications may dier
and must be observed as otherwise you could damage
the tyres and inner tubes.
I General User Manual 65
31 Warranty conditions
Read ➠ Chapter 27 "Care and maintenance of the bike"
carelly. Comply with the inspection and maintenance
intervals specied in ➠
Compliance with the service intervals is a prerequisite for
the assertion of warranty claims.
The statutory warranty period is two years. This starts
when the bike is handed over by the specialist cycle shop
who is also your contact partner for warranty claims.
As proof of purchase and date of handover, please retain
the handover document signed by both parties and record
of purchase, such as the invoice and/or sales receipt, for
the duration of the warranty period.
31.1 Prerequisites for the validity
of warranty claims
• Manufacturing, material or information error.
• The problem or error already existed at the time of
handover to the customer.
Chapter 28 "Regular inspections" .
• Non-compatible add-on components that were not
part of the scope of delivery at the time the product was handed over, or damage caused by unprofessional installation of these add-on components.
31.2 Warranty exclusions
A warranty claim applies only for the initial faultiness of
the defective part. The following are excluded om the
warranty:
• Damage caused by use in competitions, improper
use and force majeure (see ➠
use").
• All parts that are subject to nction-related wear,
providing this is not a production or material fault
(see ➠
Chapter 27.2 "Wear parts").
• Damage caused by incorrect or insucient care
and unprofessional repairs, conversions or replacement of components on the bike. This User Manual
contains detailed information on how to look aer
your bike.
• Accident damage or damage caused by other ex-
ternal factors, providing this is not attributable to
incorrect information or a product error.
• Repairs carried out with used parts or damage that
occurs as a consequence of this.
Chapter 6 "Intended
• Special equipment or accessories or non-standard
equipment; especially technical changes, i.e. to the
gearshi system or the bike fork and ame geometries.
66 I General User Manual
I General User Manual 67
We hope you thoroughly enjoy using your new bike!
Copyright © 2012 Raleigh Univega GmbH
Reproduction in whole or in part is not permitted without the consent
of Raleigh Univega GmbH. Subject to misprints, errors and technical
modications.
BionX
User Manual
™
EC Declaration of Conformity 2012
The manufacturer: Raleigh Univega GmbH
Siemensstraße 1 – 3
49661 Cloppenburg, Germany
Telephone: +49 (0) 44 71 / 92 34-0
hereby declares that the following products:
Product description:
Model designation: Alpina HT-E70, Alpina HT-E50, Terreno E
Year of manufacture: 2012
comply with all of the relevant requirements of the Machinery Directive (2006/42/EC).
Furthermore, the machine complies with all of the requirements of the
Electromagnetic Compatibility Directive (2004/108/EC).
The following harmonized standards have been applied:
DIN EN 15194 Cycles – Electrically power-assisted cycles – EPAC cycles
DIN EN 14764 City and trekking bikes – Safety requirements and test methods
Technical documentation led at:
Raleigh Univega GmbH
Siemensstraße 1 – 3
49661 Cloppenburg, Germany
Univega BionX
Olaf Flunkert
Production, Purchasing and
Technology Manager
Raleigh Univega GmbH
49661 Cloppenburg, Germany
21.09.2011
Karl-Heinz Lange
Design and Development Manager
EC Declaration of Conformity 2013
The manufacturer: Raleigh Univega GmbH
Siemensstraße 1 – 3
49661 Cloppenburg, Germany
Telephone: +49 (0) 44 71 / 92 34 - 111
hereby declares that the following products:
Product description:
Model designation: Alpina HT-E70, Alpina HT-E50, Terreno E
Year of manufacture: 2013
comply with all of the relevant requirements of the Machinery Directive (2006 / 42 / EC).
Furthermore, the machine complies with all of the requirements of the
Electromagnetic Compatibility Directive
The following harmonized standards have been applied:
DIN EN 15194 Cycles – Electrically power-assisted cycles – EPAC cycles
DIN EN 14764 City and trekking bikes – Safety requirements and test methods
Technical documentation led at:
Raleigh Univega GmbH
Siemensstraße 1 – 3
49661 Cloppenburg, Germany
Univega Xion Pedelec
(2004 / 108 / EC).
Olaf Flunkert
Production, Purchasing and
Technology Manager
Raleigh Univega GmbH
49661 Cloppenburg, Germany
14. 05. 2012
Karl-Heinz Lange
Design and Development Manager
Congratulations
Congratulations on your decision to purchase a product powered by BionX™. We are sure that your new
electric bicycle will exceed your expectations in terms of function, design, and quality. All bicycles powered
by the BionX system are manufactured with the latest production methods and high-quality materials.
Please read this manual thoroughly so that you will enjoy your new electric bicycle for years to come.
Please make sure that your new electric bicycle was professionally assembled and adjusted by your
authorized dealer, and handed over to you with the instructions. This manual serves as a supplement to the
bicycle user manual. Should you have any questions after you have studied the manual, please contact your
dealer.
User Precautions
We want you to have a fun ride, but also a safe one. Carefully read the following information,
even if you are an experienced rider. Please familiarize yourself with your electric bicycle
powered by the BionX system before you take your first trip.
1. Read all of the enclosed installation and operating instructions from the manufacturer
and follow the instructions, if any, prior to its first use.
2. Familiarize yourself with your electric bicycle and the functions of the BionX system in a safe
environment before participating in road traffic for the first time.
3. Always wear a helmet when riding an electric bicycle for your own safety.
4. Make sure that the tires have correct pressure before riding the bike.
5. Make sure that the brakes are operating properly before riding the bike.
6. Make sure that the quick-release on the front wheel is securely fastened before riding the bike.
7. Do not use a mobile phone or any other electronic devices while riding an electric bicycle; it is
imperative that you pay attention to traffic.
8. If possible, ride in bike lanes and always in the correct direction of traffic.
9. Adhere to all valid traffic regulations.
10. Keep in mind that other traffic participants may underestimate the speed of an electric bicycle.
11. Ride with both hands on the handlebars when riding your electric bicycle.
12. Ride as defensively as possible.
Thank you very much for your attention and we hope you enjoy your new electric bicycle
powered by BionX.
Your BionX Team
2
Table of Contents
User Precautions 2
Description of the BionX Propulsion System 4
BionX Propulsion System Components 4
Inserting or Removing the Console 5
Inserting and Removing the Battery 6
Handling and Charging the Battery 7
Assist Mode / Generate Mode 9
Operating the BionX Propulsion System 10
Programming the Basic Settings 12
Installing/Removing the Rear Wheel 13
Maintenance and Care 14
Cleaning 15
Transporting an Electric Bicycle on a Car 15
Repair and Spare Parts 15
Troubleshooting 16
Warranty Information and Guarantee 17
3
Description of the BionX Propulsion System
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
Your electric bicycle is an EPAC (Electrically Power Assisted Cycle) in accordance with EN 15194 and differs
from a bicycle that isn’t electrically assisted.
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
BionX Propulsion System Components
Battery
1
• Lithium Manganese (LiMn),
48V, 6.6Ah, 317Wh
• Removable, lockable
• Fully charged in: 3-4h
4
Motor
2
• DC rear hub motor
• Black, nom. 250W,
nom. 9Nm / max. 40Nm,
4.7kg
• Brushless, gearless
• Generate mode for energy
recuperation
• Integrated torque sensor
Console
3
• Removable
• Illuminated LCD display with
battery state of charge
•4assistancelevels
•4generatelevels
•Backlightcontrols
•Offerscyclecomputer
functions (speed, odometer,
average speed, total distance)
Brake switch
4
Power Supply
• A sensor integrated with the
brake lever – connected to the
BionX console
• Upon activation assistance
is shut off (“kill switch”)
generate mode is activated
• Power supply to recharge
the LiMn-battery
• Input voltage: 100-240V
• Outputvoltage:26V
• Max. charge current: 3.45A
• Output:90W
Inserting or Removing the Console
Inserting the console
• Slide the console into the console mount on the
handlebar
• Make sure that the console engages securely. When
inserted correctly, you will hear an audible “click”.
Removing the console
• Release the console by pushing the release lever
on the console mount
• Slide the console out of the console mount
5
Inserting and Removing the Battery
Inserting the battery
1
Place battery onto the docking station
2
Slide the battery down the rail gently towards connector
3
The release arm will close automatically as battery slides towards connector
Do not force the battery arm closed, this can bend the battery connector
4
With the release arm almost closed, hold it in place and simultaneously press in the lock cylinder – you
will hear an audible >click< when the battery is properly inserted
4
2
1
1” (25.4mm)
Removing the battery
1
Turn off the BionX propulsion system (no illustration)
2
Lightly press on the battery release arm, insert the key and turn clockwise
3
The lock cylinder will protract, freeing battery release arm (no illustration)
4
Remove the battery by opening release arm
5
Lift the battery from dock by sliding upwards
6
Remove the battery
3
>CLICK<
4
5 6
001
001
2
6
Handling and Charging the Battery
WARNING
BionX batteries shall only be recharged with BionX chargers or BionX power supplies.
Never short circuit the battery by connecting the contacts of the battery. Never open the
battery. This could damage the battery and possibly lead to overheating or ignition of the
battery. The battery cannot be serviced by the user. Opening the battery case voids all
warranty and product liability claims. Never use a battery which has obvious damage
to the housing or the connector.
Make sure that the battery is no longer connected to the power supply once the charging operation is
complete. The Lithium Manganese battery cells have a low self-discharge rate, therefore a continuous
connection of the battery to the power supply is not necessary. We recommend that you fully charge the
battery when it will not be used for a longer period of time, for example, before storing it for the winter,
and then recharge the battery at minimum every three months.
It is best to store the battery in a cool location at temperatures between 10 °C and 25 °C. Never store the
battery in locations where the temperatures can reach more than 45 °C or fall below -10 °C. The battery
should never be exposed to extreme temperature fluctuations or humidity, and always protect the battery
during storage from humidity to prevent corrosion on the connectors. Never drop the battery, and protect
it from physical damage. Damage may lead to short-circuits, and as a result cause overheating or ignition
of the battery.
Used batteries may not be disposed of in regular household trash!
Be aware that used batteries must be disposed of properly!
DERBY BionX batteries can be returned at DERBY dealerships free of charge.
Charging the battery:
WARNING
Only use the BionX power supply that was supplied with the bicycle to charge the battery.
The use of other power supplies can damage the battery.
The BionX power supply should be used exclusively for rechargeable batteries of the
specified type. The use of the BionX power supply with batteries that are not rechargable
may damage those and could lead to overheating, or ignition of the battery. Keep the
power supply away from water or moisture when charging and/or connected to prevent
electrical shock or short-circuits.
Do not use a power supply that has obvious signs of damage to the cable, housing or
the connector.
7
Extreme temperatures will affect battery life, especially during charging. Avoid charging in direct sunlight
or in very hot or cold temperatures. This will reduce the life of the battery considerably. We recommend
charging the battery at temperatures around 20 °C (room temperature). The battery should be warmed to
room temperature before it is charged, particularly when it was exposed to cold temperatures during a ride.
The battery can be charged when mounted on the bicycle or removed from the battery docking station.
A Lithium Manganese battery does not have a memory effect, which means that the battery’s maximum
energy capacity is not affected if it is repeatedly recharged after only being partially discharged. The battery
does not need to be completely drained before charging. We recommend charging the battery after every
ride, preferrably when the battery state of charge display shows less than 50%. We recommend that you
fully charge the battery when it will not be used for a longer period of time, for example, before
storing it for the winter, and then recharge the battery at minimum every three months. When the
battery is depleted to the level where there is risk it could fall into deep discharge, the battery will signal that
a recharge is needed by beeping.
Power Supply
The delivered power supply is suitable for the voltage ranges
110-115V or 220-230V. There is no need to manually set the
voltage range.
Charging procedure
LED-Ring green = chargedLED-Ring amber = charging
• Connect power supply and battery by inserting the charge connector into the touch port – the system
can be turned on or off
• Connect the plug of the power supply with the power outlet
• The battery touch port (LED ring around the charging connector) lights up according to the actual state
of charge of the battery and then turns to AMBER during the charging process
• After a complete charge the colour of the LED ring changes to GREEN. The battery is then fully charged
and the charging process is complete
• Following this procedure the charging connector should be disconnected
• During the charging process you can check the battery state of charge through the console if the
battery is connected to the system - system can be switched on while it is charged
The battery is fully charged after about 3 to 4 hours. Make sure that a completely charged battery is no
longer connected to the charger after the charging procedure is completed.
8
Checking Battery State of Charge
This has my vote :)
• Swipe your finger slowly over the touch port.
• Battery state of charge LED will illuminate.
Battery state Colour
100-85 % green
85-25 % amber
< 25 % red
Assist Mode / Generate Mode
The BionX propulsion system operates in four assist levels in the assistance mode, and in four charging
levels in the generate mode. In the assistance mode, your pedalling is assisted proportionally by an
electric motor that drives the rear wheel. A torque sensor is located on the axle of the electric motor and
measures the effort provided by the rider; this produces natural feeling assistance from the motor.
When in generate mode the electric motor functions as a generator and recharges the battery. When
going downhill, you can regulate your speed by varying the generate level. This generate function
provides a certain braking effect, however it does not replace legally required brakes. If either one of the
two brake levers (depending on bike model) is pulled, the drive system automatically enters generate
mode. The range can therefore be extended up to 15%, depending on the road conditions.
Assistance Level (A) Degree of Assist Riding Situation
1 35% Riding on level ground
2 75% Slight inclines, head wind
3 150% Steep hills, strong head wind
4 300% Very steep roads
Generation Level (G)
1 Slight downhill grade, tailwind
2 Significant downhill grade, tailwind
3 Steep descent
4 Very steep descent
9
Operating the BionX Propulsion System
7
6
4 3
9
5
21
9
8
1. Power
2. Key
3. Key
4. Cycle
5. State of charge
indicator
6. (bicycle) mode
7. Speedometer
8. Trip distance/odometer/
chronometer/average speed
9. Assist (A) or generate level (G)
Turn the system on
Briefl y push either the key or key. The battery will
beep 4times and you will see a countdown, this is the
system perfoming a self check. After startup, the system
is always in mode (no motor assist/bike operation).
To turn the system off, briefl y push . The battery will
beep 5 times. After 10 minutes of “no operation” the
system turns off automatically.
Select assistance/generate level
Push / key for more/less assist (see bar “fi elds 1-4”
above display “A”). From mode push key to
enter continuous generate mode.
10
Turn on display backlight
Push and hold key for 4 seconds -
4s
display backlight is turned on.
Turn off display backlight
Push and hold key again for 4 seconds.
Select the cycling computer functions
Briefl y push the key to change between:
Trip Distance DIST
Odometer ODO
Chronometer CHRONO
Average Speed AVSPD
To reset cycle computer functions
Hold the key for a few seconds to reset the distance,
chronometer, and average speed values to zero.
11
Programming the Basic Settings
In general, all basic settings for your electric bicycle are pre-set. If you happen to change tire sizes, during
service, for example, you can reset the tire circumference to ensure the precise function of your speedo meter. Furthermore, you can set the unit to display the speed, the strength of the recharge when triggering
one of the two brake levers and the arrangement of the main functions. This is done by
entering programming codes.
Turn on the programming mode
Simultaneously push and until the display shows “0000”. The fi rst zero blinks. Change the value
of the selection with or and confi rm with . Select the other digits in the same manner until the
desired program is displayed.
Code Description
2001 Select km/h or mph
2002 Regeneration/brake output (for magnetic switch) 0-40 (ideally 30-40)
2005 Tire circumference (millimeters)
2009 Flip Display Plus/Minus 0 = power left, 1 = power right
Code 2001 Code 2002
Select unit - km/h or mph. Select with
or and confi rm with .
Default value: 30: adapt with
. Confi rm with .
and
Code 2005 Code 2009
Set tire size (in mm) - Select digits
one after another with
confi rm with
or and
.
Current setting of main functions is
displayed. Flip = 0, assist toggle is
the right side of console; Flip = 1,
toggle is on the left side of console.
Confi rm with
.
assist
on
WARNING
Please do not use other programming codes without consulting your authorized dealer.
If you type the wrong code, please push key to exit programming mode.
12
Installing/Removing the Rear Wheel
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
15mm
40Nm
15mm
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
15mm
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
We recommended the removal and installation of the rear wheel to be done by a qualified dealer.
Should you have to do this yourself, please follow the instructions below:
WARNING
Always turn off the propulsion system prior to plugging in or unplugging the motor cables.
CAUTION
It is absolutely essential that the axle nuts are tightened with a torque of 40Nm/30lb-ft;
this ensures that the propulsion system functions properly. Ensure the torque reaction
collar is fully inserted into the dropout.
Hydraulic disc brake: Do not pull the brake lever with the brake disc on the rear wheel
removed from the caliper. Insertion of the wheel can be difficult or impossible as the brake
pads will prevent brake disc from sliding in place.
To Remove the rear wheel
• Make sure that the system is turned off
• Remove the neoprene covers (Fig. 1)
• Unplug the two cable connections that lead to the motor (Fig. 2)
FirstCOMMUNICATION1,thenPOWER
• Disconnect the cable guide from the rear wheel brake (only on bicycles with V-brakes)
• Loosen the axle nut on the rear wheel using a 15mm ring wrench (Fig. 3)
• Slide the rear wheel downwards out of the drop out
2
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
2
1
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
Fig. 1 Fig. 2 Fig. 3
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
15mm
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
13
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
P
O
W
E
R
E
D
B
Y
B
I
O
N
X
1
2
X
N
O
I
B
15mm
Y
B
D
E
R
E
W
O
P
40Nm
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
X
N
O
I
B
Y
B
D
E
R
E
W
O
P
Installing the rear wheel
• Guide the rear wheel axle into the two dropouts and make sure that the brake disc (on models with
disc brakes) is inserted between the brake pads
• Also make sure that the flat area at the left of the rear axle (torque reaction collar) is aligned so that it
fits into the left dropout
• Install the rear wheel with both sides of the axle inserted all the way in the dropouts
• Tighten the axle nuts on the rear wheel with 40Nm/ 30lb-ft (= VERY TIGHT!). This torque is essential for
the correct function of the propulsion system. If you do not have a torque wrench, use a normal ring
wrench. Have your dealer check the torque of the axle nuts as quickly as possible. Use only the original
axle nuts; otherwise you run the risk of damaging the axle threads.
• Keep the motor cables clear of the brake disc (on models with disc brakes)
• Pluginthecableconnections(POWER1beforeCOMMUNICATION2) and place the larger neoprene
cover over the plug-in connections, and the smaller neoprene cover closer to the disc to prevent the
cables from wear.
• Now replace the cable pull. Re-install the cable guide of the rear wheel brake (V-brakes only), and
correctly adjust the rear wheel brake.
Maintenance and Care
We recommend to have the spoke tension of the rear wheel and the torque of all screws checked by your
qualified dealer after the first 200km.
In order to ensure extended use of the propulsion system, all plug-in contacts of the system should be
checked every two to three months and cleaned with a soft and dry brush, if necessary. It must be ensured
that no dirt or humidity penetrates the battery docking station when the battery is removed. The electric
motor is a brushless DC-motor that does not have to be serviced.
14
Cleaning
115
FUSE
CAUTION
Never use a high pressure washer or a garden hose to clean the propulsion system. The force
of a water jet could damage the electrical components of the propulsion system.
We recommend a soft sponge or a soft brush to clean the bicycle. Use a moist rag to clean the battery’s
docking station. Always use very little water and keep water away from the electrical contacts. Check the
plug-in connections for moisture after cleaning and let these dry, if necessary, before reusing the bicycle.
Transporting an Electric Bicycle on a Car
WARNING
Make absolutely sure that the bike rack on your car is suitable for the increased weight
and the unique frame style of your electric bicycle. A rack that is not suitable can be
damaged or even break during the transport of the electic bicycle. The electric bicycle can
be damaged by an unsuitable bike rack.
For transportation of the electric bicycle on a bike rack always remove the battery and the console.
Repair and Spare Parts
For repair of your electric bicycle consult your qualified dealer. All of the original
spare parts for your electric bicycle can be purchased through your dealer. If you
need spare keys for the battery, please contact your dealer. Please retain the key
number for your records.
BionX Key Number
001
15
Troubleshooting
The system does not turn on
Check the battery and make sure that it is charged. The battery must be correctly inserted in the docking
station and the lock must be completely closed. Also check that all connectors of your wiring harness are
properly engaged. If the problem persists, contact your authorized dealer.
The system can be turned on but there is no assist
Check that the cables running from the battery to the motor are properly connected. If the problem persists, contact your authorized dealer.
The system is continuously in generate mode
When the propulsion system is continuously in generate mode and cannot be switched back to assist
mode by pushing the key, the problem most likely lies with the brake switches that are located at the
brake levers. In this case try to “repair” the system by turning it off and then on again. If that does not
solve the problem, you can temporarily bypass it by removing the plug-in connection from the console to
the brake-switch.
WARNING
If you bypass the brake switches you also disable regenerative breaking.
In doing so your system will not provide any brake support.
We recommend that you contact your dealer as soon as possible.
The motor is not as powerful after a repair or service
Tighten the nuts of the rear axle with the specified torque (40Nm/30lb-ft). If the problem is not solved
please contact your dealer.
The battery state of charge display on the console does not show “full” after a complete
charging procedure
Make sure that you have followed all of the instructions for the charging procedure. Let the battery cool
off for a few hours and then recharge it again. If the problem’s still not solved, let the battery cool again,
fully deplete the battery and charge it again. If the problem persists, contact your authorized dealer.
16
Warranty Information and Guarantee
1. The BionX warranty covers a two-year period for BionX propulsion system(s) within the framework of
the following conditions.
2. This warranty exclusively covers systems provided by BionX excluding all the other bicycle components
provided by other bicycle manufacturers.
3. This warranty covers the repair and/or the replacement of BionX propulsion systems provided that the
equipment concerned loses its functionality within the agreed warranty period and also provided that
the claim is not related to any of the following cases expressly excluded under this warranty.
4. Any other legal provisions, particularly with respect to warranty regulations, are not restricted by this
warranty.
5. This warranty only covers material and manufacturing defects. It is only effective with a valid proof of
purchase consisting of the original purchase document or receipt indicating the date of purchase, the
dealer’s name and the designation of the bicycle model. BionX reserves the right to reject the coverage
of this warranty if the accompanying documentation of BionX components is not accurate
or complete.
6. In the case of a warranty claim, BionX undertakes to either repair faulty system components and/or
to replace such components, at BionX discretion (Service Replacement Unit).
7. Warranty repairs have to be exclusively performed by BionX. Any component to be repaired under
the framework of this warranty has to be transferred to BionX at the client’s own expenses and risks,
and, after the completion of such repair, has to be picked up at BionX, or, it has to be shipped (at the
request of the client) to the client’s address at the client’s own expenses and risks. In the case of
rightful warranty claims, BionX reserves the right to bear or repay transportation expenses. In order
to have a previous determination whether a warranty claim is justified or not, the end user has to
submit his claim to the dealer from whom he purchased the product so that the respective dealer
handles the shipment to BionX.
8. Costs for repair work performed in advance by persons who have not been authorized by BionX
will not be reimbursed. In such a case, any warranty claim will cease.
9. Repair work and/or replacement of components during the warranty period do not lead to an
extension and/or a new start of the warranty period. Repair work and direct replacement during
the warranty period may be performed with functional replacement components of equal value.
10. The two-year warranty period starts with the date of purchase. Warranty claims must be reported
immediately.
17
11. No warranty claims are accepted - without limitation to other reasons - in the case of damages due
to the following:
a) External influences, particularly falling rocks, collision, accident and other external events with
an immediate external effect due to mechanical powers.
b) Purpose and/or malevolent acts, theft and robbery as well as natural hazard events and/or
acts of mischief.
c) Test, maintenance, repair and replacement work due to normal use.
d) If the battery/cell pack does not provide full capacity in the course of normal use or for batteries
going through a normal aging process or reduction of performance, BionX warranty only covers
that within the two-year warranty period or after 600 charging cycles, whichever event occurs first,
to the condition that the battery still provides at least 70% of its initial capacity.
e) In the case of inappropriate use, e.g. the product was exposed to liquids, chemicals of any type
and/or extreme temperatures, wetness and humidity and/or if the battery suffers damages due to
non-compliance with the special instructions set forth in the chapter “Handling and Charging of
the Battery“.
f) The model, serial or product number on BionX product has been changed, deleted, blurred or
removed. The seal (serial number sticker) on the battery housing has been broken or obviously
manipulated.
g) Use of the battery in systems that are not approved for such use with this particular product.
h) OperationoftheBionXsystemwithbatteriesotherthanthebatteriesdesignedfortheBionX
system.
i) Damages to the battery due to overcharging or not adhering to the instructions of battery handling
(refer to user manual).
12. This warranty only covers the above mentioned repair work and/or the replacement of defective or
compromised components. It excludes any claims as to the reimbursement of property damages,
downtimes, expenses for renting or leasing equipment, travel expenses, lost profit or any other claims.
BionX liability in connection with this warranty is limited to the respective acquisition value of the
product.
18
BionX, BionX Design and powered by BionX are trademarks
of BionX International Corporation.
©2011 BionX International Corporation. All Rights Reserved.
19
bionxinternational.com
Your dealer
Loading...