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TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
MY21B01 - 12_1.0_04.05.2020
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
KM/H
AMM
P MWH
MIN
MPH
KM
/H
BULLS Cross Mover Evo 1, BULLS Cross Mover Evo 2 , BULLS Cro ss Ride r Evo 1 (Münch en),
BULL S Cross Ri der Evo 2 (Cologn e), BUL LS Cross Street E1
21-15-1016 - 21-15-1018, 21-15-1027, 21-15-1028, 21-15-1069, 21-15-1070, 21-17-1013 - 21-17-1015,
21-17-1029 - 21-17-1030, 21-17-1045, 21-17-1064
MY21B01 - 12_1.0_06.07.2020 2
Contents
Contents
1 About these operating instructions 6
1.1 Manufacturer 6
1.2 Language 6
1.3 Laws, standards and directives 6
1.4 For your information 6
1.4.1 Warnings 6
1.4.2 Markups 7
1.5 Nameplate 8
1.6 Type number and model 9
1.7 Identifying the operating instructions 9
2 Safety 10
2.1 Residual risks 10
2.1.1 Risk of battery fire and explosion 10
2.1.2 Risk of fire and explosion due to short
circuit in the battery 10
2.1.3 Fire hazard caused by overheated
charger 10
2.1.4 Electric shock caused by electric drive
system 10
2.1.5 Risk of a fall due to incorrectly set quick
releases 10
2.1.6 Risk of fire and burns due to hot motor 11
2.1.7 Key breaking off 11
2.2 Toxic substances 11
2.2.1 Brake fluid 11
2.2.2 Suspension oil 11
2.2.3 Defective battery 11
2.3 Requirements for the rider 11
2.4 Vulnerable groups 11
2.5 Personal protective equipment 11
2.6 Safety markings and safety instructions 11
2.7 What to do in an emergency 12
2.7.1 Dangerous situation in road traffic 12
2.7.2 Leaked brake fluid 12
2.7.3 Battery vapours emitted 13
2.7.4 Battery fire 13
2.7.5 Leaked brake fluid 13
2.7.6 Oil and lubricant leaks from the fork 13
2.7.7 Oil and lubricant leaks from the rear
frame damper 13
3Overview 14
3.1 Description 15
3.1.1 RANGE 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.2.1 Rigid fork 15
3.1.2.2 Suspension fork 15
3.1.2.3 Steel suspension fork 16
3.1.3 Brake system 16
3.1.3.1 Disc brake 16
3.1.4 Drive system 17
3.1.5 Rechargeable battery 17
3.1.5.1 Frame battery 18
3.1.5.2 Pannier rack battery 19
3.1.5.3 Integrated battery 19
3.1.6 Display 20
3.1.7 Control panel 20
3.1.7.1 USB port 20
3.1.8 Riding light 20
3.1.9 Charger 20
3.2 Proper use 21
3.2.1 Maximum permitted total weight 22
3.2.2 Data privacy information 22
3.3 Improper use 22
3.4 Proper use 23
3.5 Improper use 24
3.5.1 Maximum permitted total weight 25
3.5.2 Data privacy information 25
3.6 Environmental requirements 26
3.7 Technical data 28
3.7.1 Pedelec 28
3.7.2 Emissions 28
3.7.3 Tightening torque 28
3.7.4 Intuvia display 28
3.7.5 USB port 28
3.7.6 Active Line motor 28
3.7.7 Active Line Plus motor 28
3.7.8 Performance Line motor 29
3.7.9 Performance Line Cruise motor 29
3.7.10 Bicycle lighting 29
3.7.11 PowerPack 300 battery 29
3.7.12 PowerPack 400 battery 29
3.7.13 PowerPack 500 battery 29
3.7.14 PowerTube 400 battery 30
3.7.15 PowerTube 500 battery 30
3.7.16 PowerTube 625 battery 30
3.7.17 BOSCH pedelec ABS BAS100 30
3.8 Description of controls and screens 31
3.8.1 Handlebars 31
3.8.2 Rechargeable battery 31
3.8.3 Display 31
3.8.4 Control panel 31
3.8.5 On-screen indicators 32
3.8.5.1 Riding light indicator 32
3.8.5.2 Level of assistance indicator 32
3.8.5.3 Battery level indicator (display screen) 32
3.8.5.4 Indicator for motor power used 33
3.8.5.5 Gear recommendation indicator 33
3.8.5.6 Tachometer indicator 33
3.8.5.7 Function display 33
3.8.5.8 Journey information 33
MY21B01 - 12_1.0_06.07.2020 3
Contents
3.8.5.9 Additional journey information 33
3.8.5.10 System settings and data 34
3.8.5.11 Additional system settings 34
3.8.6 System message 35
3.8.7 ABS indicator lamp 35
4 Transporting and storing 36
4.1 Physical transport characteristics 36
4.1.1 Weight and dimensions during
transportation 36
4.1.2 Designated handles/lifting points 36
4.2 Transporting 36
4.3 Storing 36
4.3.1 Break in operation 37
4.3.1.1 Preparing a break in operation 37
4.3.1.2 Taking out of operation 37
5 Assembly 38
5.1 Required tools 38
5.2 Unpacking 38
5.2.1 Scope of delivery 38
5.3 Preparing the battery 38
5.3.1 Checking the battery 38
5.3.2 Retrofitting a PowerTube Adapter 400
or 500 38
5.4 Commissioning 40
5.4.1 Installing the wheel in the Suntour fork 40
5.4.1.1 Screw-on axle (15 mm) 40
5.4.1.2 Screw-on axle (20 mm) 41
5.4.1.3 Quick release axle 41
5.4.1.4 Quick release 43
5.4.2 Installing the wheel in the FOX fork 44
5.4.2.1 Quick release (15 mm) 44
5.4.2.2 Kabolt axle 45
5.4.3 Checking the stem and handlebars 45
5.4.3.1 Checking the connections 45
5.4.3.2 Firm hold 45
5.4.3.3 Checking the headset backlash 45
5.5 Pedelec sale 45
6 Operation 46
6.1 Risks and hazards 46
6.1.1 Personal protective equipment 47
6.2 Tips for a greater range 47
6.3 Error message 48
6.3.1 Display 48
6.3.2 Rechargeable battery 50
6.4 Instruction and customer service 51
6.5 Adjusting the pedelec 51
6.5.1 Adjusting the saddle 51
6.5.1.1 Adjusting the saddle tilt 51
6.5.1.2 Determining the seat height 51
6.5.1.3 Adjusting the seat height with quick
release 52
6.5.1.4 Adjusting the seat position 52
6.5.2 Adjusting the handlebars 53
6.5.3 Adjusting the stem 53
6.5.3.1 Adjusting the height of the handlebars 53
6.5.3.2 Adjusting the quick release clamping
force 53
6.5.4 Retracting the brake linings 53
6.5.5 Adjusting the Suntour fork 54
6.5.5.1 Adjusting the negative deflection 54
6.5.5.2 Adjusting the steel suspension fork
negative deflection 54
6.6 Accessories 55
6.6.1 Child seat 55
6.6.2 Trailer 56
6.6.3 Pannier rack 56
6.7 Check list before each ride 57
6.8 Using the kickstand 58
6.8.1 Raising the kickstand 58
6.8.1.1 Parking the pedelec 58
6.9 Using the pannier rack 58
6.10 Rechargeable battery 59
6.10.1.1 Removing the frame battery 59
6.10.2.1 Removing the pannier rack battery 59
6.10.4 Charging the battery 61
6.10.5 Charging the dual battery 61
6.10.5.1 Charging process when two batteries
are used 61
6.10.5.2 Charging process when one battery
is used 62
6.10.6 Using double battery model with a
single battery only 62
6.10.7 Waking the battery 62
6.11 Electric drive system 63
6.11.1 Switching on the electric drive system 63
6.11.2 Switching off the drive system 63
6.12 Control panel with display 64
6.12.1 Removing and attaching the display 64
6.12.1.1 Removing the display 64
6.12.1.2 Attaching the display 64
6.12.2 Securing the display against removal 64
6.12.3 Charging the display battery 64
6.12.3.1 Charging on the pedelec 65
6.12.3.2 Charging using the USB port 65
6.12.4 Using the USB port 65
6.12.5 Switching on the display 65
6.12.6 Switching off the display 65
6.12.7 Using the push assist system 65
6.12.8 Using the riding light 65
6.12.9 Selecting the level of assistance 66
6.12.10 Journey information 66
6.12.10.1Switching the displayed journey
information 66
6.12.10.2Resetting the journey information 66
6.12.11 Changing the system settings 66
MY21B01 - 12_1.0_06.07.2020 4
Contents
6.13 Brake 67
6.13.1 Using the brake lever 68
6.14 Suspension and damping 69
6.15 Gear shift 70
7 Cleaning and servicing 71
7.1 Cleaning after each ride 71
7.1.1 Cleaning the suspension fork 71
7.1.2 Cleaning the pedals 71
7.2 Basic cleaning 72
7.2.1 Cleaning the frame 72
7.2.2 Cleaning the stem 72
7.2.3 Cleaning the wheel 72
7.2.4 Cleaning the drive elements 72
7.2.5 Cleaning the chain 73
7.2.6 Cleaning the battery 73
7.2.7 Cleaning the display 73
7.2.8 Cleaning the motor 73
7.2.9 Cleaning the brake 74
7.3 Servicing 74
7.3.1 Servicing the frame 74
7.3.2 Servicing the stem 74
7.3.3 Servicing the fork 74
7.3.4 Servicing the drive elements 74
7.3.5 Servicing the pedals 74
7.3.6 Servicing the chain 74
7.4 Maintenance 75
7.4.1 Wheel 75
7.4.1.1 Checking the tyres 75
7.4.1.2 Checking the rims 75
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 75
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve 76
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 76
7.4.2 Brake system 76
7.4.3 Checking the brake linings for wear 76
7.4.4 Checking the pressure point 77
7.4.5 Checking the brake discs for wear 77
7.4.6 Checking electrical cables and
brake cables 77
7.4.7 Checking the gear shift 77
7.4.8 Checking the stem 77
7.4.9 Checking the USB port 77
7.4.10 Checking the chain tension 77
8 Maintenance 78
8.1 Suspension system 79
8.1.1 Rear frame damper 79
8.1.2 Suspension fork 80
8.1.3 Suspension seat post 81
8.2 Axle with quick release 81
8.2.1 Checking the quick release 82
8.3 Maintaining the stem 82
8.4 Adjusting the gear shift 82
8.4.1 Cable-operated gear shift, single-cable 83
8.4.2 Cable-operated gear shift, dual-cable 83
8.4.3 Cable-operated twist grip, dual-cable 83
9 Troubleshooting, fault clearance and
repair 84
9.1 Troubleshooting and fault clearance 84
9.1.1 The drive system or display do not
start up 84
9.1.2 Error message 84
9.1.3 Assistance function errors 84
9.1.4 Battery error 85
9.1.5 Display errors 86
9.1.6 Lighting does not work 87
9.1.7 Other errors 87
9.2 Repair 88
9.2.1 Original parts and lubricants 88
9.2.2 Replacing the lighting 88
9.2.3 Adjusting the headlight 88
9.2.4 Tyre clearance check 88
10 Recycling and disposal 89
11 Documents 90
11.1 Parts list 90
11.1.1 Bulls Cross Mover Evo 1 90
11.1.2 Bulls Cross Mover Evo 2 91
11.2 Assembly report 92
11.3 Maintenance instructions 94
11.4 Charger operating instructions 97
12 Glossary 105
12.1 Abbreviations 107
12.2 Simplified terms 107
Appendix 108
I Translation of the original EC/EU
Declaration of Conformity 108
II Declaration of conformity for
incomplete machine 109
14 Keyword index 112
MY21B01 - 12_1.0_06.07.2020 5
About these operating instructions
Thank you for your trust!
BULLS pedelecs are premium quality bicycles.
You have made an excellent choice. Your
specialist dealer will provide you with guidance
and instruction and assemble your product. Your
specialist dealer will also be happy to assist you in
the future, whether you require maintenance,
conversion or repair.
You are receiving these operating instructions
with your new pedelec. Please take time to
become familiar with your new pedelec. Use the
tips and suggestions in the operating instructions.
They will help you to enjoy your pedelec for a long
time to come. We hope you have fun and wish you
well on all of your rides!
The operating instructions are mainly designed for
the rider or the operator. They aim to ensure that
non-professionals can use the pedelec safely.
Download the operating instructions onto your
phone at the following link, so that you can use
them when you are out riding:
www.bulls.de/service/
downloads.
Copyright
© ZEG Zweirad-Einkaufs-Genossenschaft eG
Distribution or reproduction of these operating
instructions and utilisation or communication of
their content is prohibited unless expressly
approved. Any infringement will render the
offender liable for compensation. All rights
reserved in the event that a patent, utility model or
industrial design is registered.
Editing
Text and images:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Translation:
RKT Übersetzungs- und Dokumentations-GmbH
Markenstrasse 7
40227 Düsseldorf, Germany
Notice
These operating instructions are not a substitute
for personal instruction by the supplying specialist
dealer.
These operating instructions are an integral part
of the pedelec. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Sections are also designed especially for the
specialist dealer. These sections aim to ensure
that specialist dealers complete initial assembly
and maintenance safely and reliably. The
sections for specialist dealers are highlighted in
grey and marked with a spanner symbol.
MY21B01 - 12_1.0_06.07.2020 6
About these operating instructions
1 About these operating
instructions
1.1 Manufacturer
The pedelec manufacturer is:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Tel.: +49 221 17959 0
Fax: +49 221 1795931
E-mail: info@zeg.de
Subject to internal changes
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes are included in a new
published version of the operating instructions.
You will find any modifications to these operating
instructions at:
www.bulls.de/service/downloads.
1.2 Language
The original operating instructions are written in
German. A translation is invalid without the
original operating instructions.
1.3 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
Machinery Directive 2006/42/EC
Electromagnetic Compatibility Directive
2014/30/EU
ISO 20607:2018 Safety of machinery
Instruction handbook General drafting
principles
EN 15194:2018 Cycles – Electrically power
assisted cycles – pedelec bicycles
EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
ISO 17100:2016-05 Translation Services
Requirements for translation services.
1.4 For your information
Different markings are used in the operating
instructions to make them easier to read.
1.4.1 Warnings
Warnings indicate hazardous situations and
actions. You will find warnings in the operating
instructions:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries if ignored.
Low-risk hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 7
About these operating instructions
1.4.2 Markups
You will find stylised forms of typeface in the
operating instructions:
Instructions for specialist dealers are highlighted
in grey. They are indicated by a screwdriver
symbol. Information for specialist dealers does
not require non-professionals to take any action.
Stylised form Use
Italics Glossary term
Underlined in blue Link
Underlined in grey Cross references
Check marks Requirements
Triangle Instruction for action
1Instruction for
action
Several instructions for
action in specified order
Result of the action
SPACED Indicators on the display
screen
Bulleted lists
Only applies to pedelecs
with this equipment Each type has a different
kind of equipment. A
note beneath the head-
ing indicates compo-
nents which can be used
as an alternative.
Table 1: Markups
MY21B01 - 12_1.0_06.07.2020 8
About these operating instructions
1.5 Nameplate
The nameplate is situated on the frame. You can
see the exact position of the nameplate in Figure 2.
You will find thirteen pieces of information on the
nameplate.
Figure 1: Example Nameplate
No. Designation Description
1CE marking The manufacturer uses the CE marking to declare that the pedelec complies with
applicable requirements.
2 Manufacturer's contact details You can contact the manufacturer at the address. You can find more information in
Section 1.
3 Type number All pedelec models have an eight-digit type number, which is used to specify the design
model year, the type of pedelec and the version. You can find more information in
Section 1.
4 Maximum continuous power The maximum continuous power is the greatest possible power for the electric motor
output shaft over 30 minutes.
5 Maximum permitted total weight The maximum permitted total weight is the weight of the fully assembled pedelec with the
rider and baggage.
6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2019 to July 2020.
7 Pedelec type You can find more information in Section 3.2.
8 Safety markings You can find more information in Section 1.4.
9 Disposal instructions You can find more information in Section 10.
10 Area of use You can find more information in Section 3.6.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version concerned. The year of manufacture is different to the model
year in some cases.
12 Weight of the ready-to-ride pedelec The weight of the ready-to-ride pedelec is specified as a weight of 25 kg or above and
refers to its weight at the time of purchase. You must add each additional accessory to
the weight.
13 Shut-off speed The speed that the pedelec reaches at the moment when the current has dropped to zero
or to the no-load current value.
Table 2: Nameplate details
ZEG Zweirad-Einkaufs-
Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
Typ:
21-17-1017
0,25 kW / 25 km/h
zGG 150 kg
EPAC 25 kg
BJ 2020 / MJ 2021
EN 15194
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
MY21B01 - 12_1.0_25.06.2020 9
About these operating instructions
1.6 Type number and model
These operating instructions are an integral part
of pedelecs with the type numbers:
1.7 Identifying the operating
instructions
The Identification number position is located on
bottom left-hand side on each page. The
identification number is composed of the
document number, the version number and the
release date.
Type no. Model Pedelec type
Table 3: Type number, model and pedelec type
Identification number MY21B01 - 12_1.0_09.07.2020
21-15-1016 BULLS Cross Mover
Evo 1, Trapez
21-15-1018 BULLS Cross Mover
Evo 1, Wave
21-15-1027 BULLS Cross Rider Evo 1
(München), Gent
21-15-1028 BULLS Cross Rider Evo 1
(München), Trapez
21-15-1069 BULLS Cross Street E1,
Gent
21-15-1070 BULLS Cross Street E1,
Trapez
21-17-1013 BULLS Cross Mover
Evo 2, Gent
21-17-1014 BULLS Cross Mover
Evo 2, Trapez
21-17-1015 BULLS Cross Mover
Evo 2, Wave
21-17-1029 BULLS Cross Rider Evo 2
(Cologne), Gent
21-17-1030 BULLS Cross Rider Evo 2
(Cologne), Trapez
21-17-1045 BULLS Cross Rider Evo 2
(Cologne), Wave
21-17-1064 BULLS Cross Mover
Evo 2, 26, Wave
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
City and trekking
bicycle
MY21B01 - 12_1.0_25.06.2020 10
Safety
2 Safety
2.1 Residual risks
2.1.1 Risk of battery fire and explosion
The safety electronics may fail if the batteries are
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Only use and charge the battery and
accessories if they are in perfect condition.
Never open or repair the battery.
Batteries with external damage must be
removed from service immediately.
If a battery is dropped or struck, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods. Dispose
of faulty batteries in the correct manner. Store
battery in a dry place until disposal. Never
store in the vicinity of flammable substances.
The battery is only protected from spray water.
Penetration by water can cause a short circuit.
The battery may self-ignite and explode.
Never immerse the battery in water.
Put battery out of service if you suspect water
has penetrated it.
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. The battery may self-ignite and
explode.
Protect the battery against heat.
Never store next to hot objects.
Never expose the battery to sustained direct
sunlight.
Avoid wide temperature fluctuations.
2.1.2 Risk of fire and explosion due to
short circuit in the battery
Metal objects may connect the battery's electrical
terminals. The battery may self-ignite and
explode.
Never insert paper clips, screws, coins, keys
and other small parts into the battery.
Chargers with excessive voltage damage
batteries. This may result in fire or an explosion.
Only use batteries approved for the pedelec.
Clearly label the supplied charger.
2.1.3 Fire hazard caused by overheated
charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in fire
or burns to the hands.
Never use charger on a highly flammable
surface.
Never cover the charger during charging.
Never leave the battery unattended during
charging.
2.1.4 Electric shock caused by electric
drive system
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
2.1.5 Risk of a fall due to incorrectly set
quick releases
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
MY21B01 - 12_1.0_25.06.2020 11
Safety
2.1.6 Risk of fire and burns due to hot
motor
The motor housing becomes hot when riding.
Touching it may cause burns to the skin or other
objects.
Never touch the motor housing directly after
riding.
Never place the pedelec on a flammable
surface, such as grass or wood, directly after
use.
2.1.7 Key breaking off
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key to the battery lock.
2.2 Toxic substances
2.2.1 Brake fluid
Brake fluid may leak out after an accident or due
to material fatigue. Brake fluid can be fatal if
swallowed or inhaled.
Never dismantle the brake system.
Avoid contact with skin.
Do not inhale vapours.
2.2.2 Suspension oil
Suspension oil in the fork and the rear frame
damper is toxic to the touch, irritates respiratory
tracts and causes cancer, sterility and mutation in
germ cells.
Never dismantle the rear frame damper or the
suspension fork.
Avoid contact with skin.
2.2.3 Defective battery
Liquids and vapours may leak from damaged or
faulty batteries. Excessively high temperatures
may also cause liquids and vapours to leak from
the battery. Such liquids and vapours can irritate
the airways and cause burns.
Never dismantle the battery.
Avoid contact with skin.
Do not inhale vapours.
2.3 Requirements for the rider
The rider must demonstrate adequate physical,
motor and mental abilities to ride on public roads.
A minimum age of 14 years is recommended.
2.4 Vulnerable groups
Keep batteries and charger away from children
and people with reduced physical, sensory or
mental capabilities or lacking in experience and
knowledge.
If minors use the pedelec, a legal guardian must
should provide them with comprehensive
instructions.
2.5 Personal protective equipment
Wear a suitable cycling helmet, sturdy footwear
and typical close-fitting clothing to provide
protection.
2.6 Safety markings and safety
instructions
The nameplate contains these safety markings
and safety instructions:
Symbol Explanation
General warning
Adhere to the instructions for use
Table 4: Meaning of safety markings
MY21B01 - 12_1.0_25.06.2020 12
Safety
2.7 What to do in an emergency
2.7.1 Dangerous situation in road traffic
In the event of any hazards or dangers in road
traffic, apply the brakes on the pedelec until it
comes to a halt. The brake acts as an
emergency stop system in such cases.
2.7.2 Leaked brake fluid
Remove those affected from the danger area to
fresh air.
Never leave those affected unattended.
Immediately remove any clothing items
contaminated with brake fluid.
Never inhale vapours. Ensure sufficient
ventilation.
Wear gloves and safety gloves as protective
equipment.
Keep unprotected persons away.
Take care with leaked brake fluid as it poses a
slip hazard.
Keep leaked brake fluid away from naked
flames, hot surfaces and sources of ignition.
Avoid contact with skin and eyes.
After inhalation
Take in fresh air. Immediately consult a doctor
in case of any discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Rinse eyes under flowing water for at least ten
minutes with the lids open; also rinse under
lids. Immediately consult a doctor in case of
any pain or discomfort.
After swallowing
Rinse out mouth with water. Never induce
vomiting. Risk of aspiration!
If a person is lying on their back and vomiting,
place them in the recovery position. Seek
medical advice immediately.
Environmental protection measures
Never allow brake fluid to flow into the sewage
system, water courses or groundwater.
Notify the relevant authorities if fluid
penetrates the ground, water courses or the
sewage system.
Consult a doctor immediately in the event of
any pain or discomfort caused by combustion
gas or leaking fluids.
Symbol Explanation
Read the instructions
Separate collection of electrical
and electronic devices
Separate collection of ordinary
and rechargeable batteries
Must not be thrown into fire
(burning prohibited)
It is forbidden to open any
batteries
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct sunlight
Table 5: Safety instructions
max. 50°C
MY21B01 - 12_1.0_25.06.2020 13
Safety
2.7.3 Battery vapours emitted
Vapours may be emitted if the battery is damaged
or used improperly. The vapours may cause
respiratory tract irritation.
Get into fresh air.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Carefully rinse eyes with plenty of water for at
least 15 minutes. Protect unaffected eye. Seek
medical advice immediately.
After skin contact
Remove any solid particles immediately.
Rinse the affected area with plenty of water for
at least 15 minutes. Then dab the affected skin
gently. Do not rub dry.
Remove contaminated clothing immediately.
Immediately consult a doctor if there is any
redness, pain or discomfort.
2.7.4 Battery fire
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
1Keep your distance if the battery becomes
deformed or starts to emit smoke.
2If charging, remove the plug connector from
the socket.
3Contact the fire service immediately.
Use Class fire extinguishers to put out the fire.
Never extinguish damaged batteries with water
or allow them to come into contact with water.
Inhaling vapours can cause intoxication.
Stand on the side of the fire where the wind is
blowing from.
Use breathing apparatus if possible.
2.7.5 Leaked brake fluid
The brake system must be repaired immediately if
brake fluid leaks out. Dispose of leaking brake
fluid in an environmentally responsible way in
accordance with statutory regulations.
Contact your specialist dealer.
2.7.6 Oil and lubricant leaks from the fork
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in compliance with statutory
regulations.
Contact your specialist dealer.
2.7.7 Oil and lubricant leaks from the rear
frame damper
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in accordance with statutory
regulations.
Contact your specialist dealer.
MY21B01 - 12_1.0_25.06.2020 14
Overview
3Overview
Figure 2: Pedelec viewed from right, Bull Cross Rider used as example
1Front wheel
2Fork
3 Front guard
4 Headlight
5Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Reflector
11 Pannier rack
12 Rear guard
13 Rear light
14 Rear wheel
15 Chain
16 Frame number
17 Battery and nameplate
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 16 17
MY21B01 - 12_1.0_25.06.2020 16
Overview
3.1.2.3 Steel suspension fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6).
Figure 5: Example showing Suntour fork
Other elements: the setting wheel for negative
deflection (9), crown (3), Q-Loc (5), dust seal (4),
fork end (7) and stanchion (8)
3.1.3 Brake system
Every pedelec has a hydraulic brake system. The
brake fluid is in a closed hose system. If the rider
pushes the brake lever, the brake fluid activates
the brake on the wheel.
The pedelec has either:
a rim brake on the front and rear wheels
a disc brake on the front and rear wheels or
a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the bicycle to a
halt quickly and safely in the event of an
emergency.
3.1.3.1 Disc brake
Figure 6: Brake system with disc brake – example
1Brake disc
2 Brake calliper with brake linings
3Handlebars with brake lever
4 Front wheel brake disc
5 Rear wheel brake disc
On a pedelec with a disc brake, the brake disc is
screwed permanently to the wheel hub. The brake
lever is pushed to increase brake pressure. The
brake fluid is used to transfer pressure through
the brake lines to the cylinders in the brake
calliper. The braking force is boosted by a speed
reduction and applied to the brake linings. These
apply the brake disc mechanically. If the brake
lever is pushed, the brake linings are pressed
against the brake disc and the wheel movement is
decelerated until it comes to a stop.
1
1
2
3
4
5
6
8
9
7
1
2
3
4
5
MY21B01 - 12_1.0_06.07.2020 18
Overview
The battery has a high energy content when
charged. You will find codes of practice for their
safe handling in Section 2 Safety and Section 6.9
Rechargeable battery in the operating
instructions.
If the electric drive system is not used for about
10 minutes and no button has been pressed on
the display or the control panel, the electric drive
system and the battery are automatically switched
off to save energy.
The type and duration of operating conditions
have a significant effect on the battery life. Just
like any other lithium-ion battery, the battery will
age naturally if it is not being used. The battery's
service life can be extended if the battery is well
maintained and stored at the correct temperature.
The charging capacity will decrease with age,
even if the battery is maintained properly. If the
operating time is severely shortened after
charging, this is a sign that battery has reached
the end of its useful life.
Battery performance is reduced when the
temperature drops since this increases electrical
resistance. As a result, you can expect the range
to be shorter than normal in winter. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
The pedelec features either an integrated battery,
a pannier rack battery or a frame battery. Each
battery has its own lock.
3.1.5.1 Frame battery
Three different types of frame batteries can be
fitted:
Figure 9: Details of frame battery
1 Battery housing
2 Battery lock
3 Battery key
4 On-Off button (battery)
5 Battery level indicator (battery)
6 Charging port cover
7 Charging port
PowerPack 300 PowerPack 400 PowerPack 500
Table 6: Overview of frame batteries
1
2
3
4
5
678
MY21B01 - 12_1.0_06.07.2020 19
Overview
3.1.5.2 Pannier rack battery
Three different types of pannier rack batteries can
be fitted:
Figure 10: Overview of pannier rack battery
Figure 11: Details of pannier rack battery
1 Battery housing
2 Charging port
3 Charging port cover
4Battery lock
5Battery key
6 Battery level indicator (battery)
7 On-Off button (battery)
3.1.5.3 Integrated battery
Three different types of pannier rack batteries can
be fitted:
Figure 12: Overview of frame batteries
Figure 13: Integrated battery in detail
1 Battery key
2 Retainer guard
3 Securing hook
4 On-Off button (battery)
5 Battery level indicator (battery)
6 Battery housing
PowerPack 300 PowerPack 400 PowerPack 500
1
2
3
4
5
6
78
PowerTube 400 PowerTube 500 PowerTube 625
(vertical and horizontal)
1
2
3
4
5
2
6
MY21B01 - 12_1.0_06.07.2020 20
Overview
3.1.6 Display
The model series to which these instructions
apply features the BOSCH Intuvia display. In addi-
tion to the functions described here, software
changes may be introduced to rectify errors and
extend functions at any time. The display controls
the electric drive system with four operating ele-
ments and shows the journey data. The rider can
switch off the electric drive system by removing
the display. The battery powers the display if the
display is inserted in the mount, a sufficiently
charged battery is inserted into the pedelec and
the electric drive system is switched on.
If the rider removes the display from its mount, the
display is powered by a display battery. The
display battery cannot be replaced.
Figure 14: BOSCH Intuvia display
3.1.7 Control panel
The control panel controls the electric drive
system.
Figure 15: Control panel overview
3.1.7.1 USB port
There is a USB port beneath the rubber cover on
the right-hand edge of the display.
3.1.8 Riding light
When the riding light is activated, the headlight
and the rear light are switched on together.
3.1.9 Charger
Each pedelec is supplied with a charger. As a
general rule, any BOSCH charger may be used:
The 2 A compact charger
The 4 A standard charger
The 6 A fast charger
Observe the operating instructions in the
Section 11 on Documents.
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
P MWH
MIN
MPH
KM
/H
MY21B01 - 12_1.0_25.06.2020 22
Overview
3.2.1 Maximum permitted total weight
The pedelec may only be loaded to its maximum
permitted total weight (PTW). The maximum
permitted total weight is the weight of the fully
assembled pedelec with the rider and baggage.
3.2.2 Data privacy information
When the pedelec is connected to the BOSCH
diagnosis tool, data is transferred to Bosch eBike
Systems (Robert Bosch GmbH) regarding the use
of rechargeable battery, including its temperature
and cell voltage, to help improve the product. You
will find more detailed information on the BOSCH
website: www.bosch-ebike.com/en/.
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the pedelec in the following
ways:
when the electrical drive system has been
manipulated
riding with a damaged or incomplete pedelec
riding over steps
riding through deep water
charging with an incorrect charger
lending the pedelec to untrained riders
carrying other people
riding with excessive baggage
riding with no hands
riding on ice and snow
improper servicing
improper repair
tough areas of use, such as professional
competitions
stunt riding or acrobatics.
Type no. Model PTW
21-17-1013 Bulls Cross Mover Evo 2 150 kg
21-17-1014 Bulls Cross Mover Evo 2 150 kg
21-17-1015 Bulls Cross Mover Evo 2 150 kg
21-17-1016 Bulls Cross Mover Evo 1 150 kg
21-17-1017 Bulls Cross Mover Evo 1 () 150 kg
21-17-1018 Bulls Cross Mover Evo 1 150 kg
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 8: Information on improper use
MY21B01 - 12_1.0_25.06.2020 24
Overview
3.5 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the pedelec in the following
ways:
when the electrical drive system has been
manipulated
riding with a damaged or incomplete pedelec
riding over steps
riding through deep water
charging with an incorrect charger
lending the pedelec to untrained riders
carrying other people
riding with excessive baggage
riding with no hands
riding on ice and snow
improper servicing
improper repair
tough areas of use, such as professional
competitions
stunt riding or acrobatics.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 10: Information on improper use
MY21B01 - 12_1.0_06.07.2020 28
Overview
3.7 Technical data
3.7.1 Pedelec
3.7.2 Emissions
*The safety requirements as per Electromagnetic Compatibility
Directive 2014/30/EU have been met. The pedelec and the
charger can be used in residential areas without restriction.
3.7.3 Tightening torque
*if there is no other data on the component
3.7.4 Intuvia display
3.7.5 USB port
3.7.6 Active Line motor
3.7.7 Active Line Plus motor
Transportation temperature C - 2C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 10 °C - 30 °C
Ideal storage temperature 10 °C - 15 °C
Operating temperature C - 3C
Work environment temperature 15 °C - 25 °C
Charging temperature C - 4C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 13: Pedelec technical data
A-weighted emission sound pressure
level
<70dB(A)
Total vibration level for the hands and
arms
<2.5m/s²
Highest effective value of weighted
acceleration for the entire body
<0.5m/s²
Table 14: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 15: Tightening torque values
Internal lithium ion battery 3.7 V, 230 mAh
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +50 °C
Charging temperature C - + 4C
Protection rating
(with USB cover closed)
IP54
Weight about 0.15 kg
Table 16: Intuvia display technical data (BUI255)
Charge voltage 5V
Charging current Max. 500 mA
Table 17: USB port technical data
Maximum continuous power 250 W
Max. torque 40 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 2.9 kg
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +40 °C
Table 18: Technical data for Active Line BDU310 motor
Maximum continuous power 250 W
Max. torque 50 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 3.2 kg
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +40 °C
Table 19: Technical data for Active Line Plus BDU350 motor
MY21B01 - 12_1.0_06.07.2020 29
Overview
3.7.8 Performance Line motor
3.7.9 Performance Line Cruise motor
3.7.10 Bicycle lighting
3.7.11 PowerPack 300 battery
3.7.12 PowerPack 400 battery
3.7.13 PowerPack 500 battery
Maximum continuous power 250 W
Max. torque 65 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 3.2 kg
Operating temperature -5 - +40 °C
Storage temperature -10 - +40 °C
Table 20: Technical data for Performance Line BDU365 motor
Maximum continuous power 250 W
Max. torque 63 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 4 kg
Operating temperature -5 °C - +40 °C
Storage temperature -1C - +5C
Table 21: Technical data for Performance Line Cruise
BDU250P motor technical
Voltage about 12 V
Maximum output
Front light 17.4 W
Rear light 0.6 W
Table 22: Bicycle lighting technical data
Nominal voltage 36 V
Nominal capacity 8.2 Ah
Energy 300 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 23: Technical data for PowerPack 300, BBS245 and
BBR245 batteries
Nominal voltage 36 V
Nominal capacity 11 Ah
Energy 400 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 24: Technical data for PowerPack 400, BBS265 and
BBR265 batteries
Nominal voltage 36 V
Nominal capacity 13.4 Ah
Energy 500 Wh
Weight 2.6/ 2.7 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 25: Technical data for PowerPack 500, BBS275 and
BBR275 batteries
MY21B01 - 12_1.0_09.07.2020 32
Overview
3.8.5 On-screen indicators
The display has seven on-screen indicators:
Figure 20: On-screen indicators overview
1 Riding light indicator, see Section 3.8.5.1.
2 Level of assistance indicator, see Section
3.8.5.2.
3 Motor power used indicator, see Section
3.8.5.4.
4 Battery level indicator (display screen), see
Section 3.8.5.3.
5 Gear recommendation indicator, see Section
3.8.5.5.
6 Tachometer indicator, see Section 3.8.5.6.
7 Function display, see Section 3.8.5.7.
3.8.5.1 Riding light indicator
The riding light indicator lights up when the riding
light is activated.
3.8.5.2 Level of assistance indicator
The higher the selected level of assistance, the
more the electric drive system assists the rider
when pedalling. These levels of assistance are
available.
3.8.5.3 Battery level indicator (display
screen)
The battery level indicator displays the pedelec
battery level, not the level for the display internal
battery. If the display is removed from its mount,
the last level message is saved. Each bar in the
battery symbol on the screen represents about
20% capacity.
If a pedelec is used with two batteries, the battery
level indicator shows the charge level for both
batteries.
If both batteries are being charged on a pedelec,
the function display shows the charging progress
for both batteries. You can see which of the two
batteries is currently being charged by the
flashing indicator on the battery.
Figure 21: The left-hand battery is being charged
You can also see the battery charge level on the
level indicator LEDs (battery).
Level of assistance Use
SPORT Powerful assistance, for sport rides on
mountainous rides and on urban roads.
eMTB (instead of SPORT) effective assistance
with optimum efficiency for maximum
range.
TURBO Maximum assistance up to high
pedalling frequencies for sport riding.
TOUR Constant assistance, for long-range
tours
ECO Effective assistance with maximum
efficiency for maximum range.
Table 30: Overview of levels of assistance, standard
5
1
2
3
4
6
7
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM/H
5
Symbol Meaning
The battery is fully charged.
The battery needs to be recharged.
The LEDs on the battery level indicator have
gone out. The capacity for drive assistance has
been used up and assistance is gently switched
off. The remaining capacity is reserved for
lighting and the display. The screen flashes.
The battery capacity is sufficient for about
2 hours more lighting. Other electrical loads,
such as automatic gears and charging of
external devices connected to the USB port,
are not taken into account here.
Table 31: Overview of battery level indicator
OF
MP
H
KM
/
MY21B01 - 12_1.0_09.07.2020 34
Overview
Applies only to eShift with NuVinci H|Sync/enviolo with
Optimized H|Sync
The following additional functions are available on
the function display:
Applies only to eShift with Rohloff E-14 Speedhub 500/14
The following additional functions are available on
the function display:
3.8.5.10 System settings and data
In order to see the system settings and data, the
rider has to call up the system settings. The rider
can change the values of the system settings, but
not the system data.
3.8.5.11 Additional system settings
Applies only to eShift with Shimano DI2 automatic hub gears
Applies only to eShift with manual Shimano DI2 hub gears.
indicator Change
± NUVINCI CADENCE /
± NUVINCI GEAR
The current gear shift is shown
on the display screen. The new
gear is shown briefly on the
screen each time it is changed.
The standard setting is
± NuVinci cadence.
Table 37: Changing the system settings
INDICATOR Change
GEAR
The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 38: Changing the system settings
indicator Function
- CLOCK + Changes the time
- WHEEL CIRC UM + Wheel circumference in mm
- ENGLISH + Changes the language
- UNIT KM/MI + Selects whether the speed and
distance are displayed in
kilometres or miles
- TIME FORMAT + Select whether the time is
displayed in 12-hour clock or
24-hour clock format
- SHIFT RECOM.OFF + Switches the gear
recommendation on and off
Table 39: Changeable system settings
indicator Function
POWER ON HOURS Display of the total journey duration
DISPL. VX.X.X.X Display software version
DU VX.X.X.X Drive system software version
DU# XXXX XXXXX Drive system serial number
SERVICEMM/YYYY (Alternative) defined inspection
date
SERV. XX KM/MI (Alternative) defined inspection
BAT. VX.X.X.X Software version
1.BAT VX.X.X.X Software version
2.BAT VX.X.X.X Software version
Table 40: System information, unvarying
indicator Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position
– –. This menu option is only
shown when the display is
positioned in its mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer's operating
instructions. Make the fine
adjustment as soon as you hear
any unusual noises from the gear
shift. This menu option is only
shown when the display is
positioned in its mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 41: Changing the system settings
indicator Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position –
–. This menu option is only shown
when the display is positioned in its
mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer's operating
instructions. Make the fine
adjustment as soon as you hear any
unusual noises from the gear shift.
This menu option is only shown
when the display is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the display is positioned in its
mount. This menu option is only
shown if you have an electronic
control gear.
Table 42: Changing the system settings
MY21B01 - 12_1.0_06.07.2020 39
Assembly
2Use a ratchet to remove the two 4 mm hexagon
screws in the PowerTube adapter. If you don't
have a ratchet, you can use a hexagonal key to
remove the screws.
Figure 23: Removing the 4 mm hexagon screws
3Use a ratchet to remove the two 4 mm hexagon
screws in the PowerTube adapter.
Figure 24: Removing hexagon screws
4Pull out the PowerTube adapter.
Figure 25: Pulling out the PowerTube adapter
5Use adapter plates to adjust the distance if
necessary.
Figure 26: Fitted adapter plates
6Use a TORX® T25 wrench to fasten the screws
into the battery mount.
Figure 27: Fastening the battery mount
MY21B01 - 12_1.0_06.07.2020 40
Assembly
5.4 Commissioning
Only trained specialist staff may perform initial
commissioning since initial commissioning of the
pedelec requires special tools and specialist
knowledge.
Experience has shown that a pedelec which has
not yet been sold is automatically handed to
customers as soon as it appears ready to ride.
For this reason, every pedelec must be
prepared, so it is fully ready for use
immediately after being assembled.
The assembly report (see Section 11.2)
describes all safety-relevant inspections, tests
and maintenance tasks for the bicycle in a
separate list. All assembly work must be
completed to ensure the pedelec is ready to
ride.
Complete an assembly report for quality
assurance purposes.
5.4.1 Installing the wheel in the Suntour
fork
5.4.1.1 Screw-on axle (15 mm)
Only applies to Suntour forks with 15 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 28: Fully inserting the axle
2Tighten the axle to 8–10 Nm with a 5 mm
hexagon socket spanner.
Figure 29: Tightening the axle
3Insert the securing screw on the non-drive
side.
Figure 30: Pushing the quick release lever into the axle
Burns from hot drive
The drive cooler can become extremely hot
during use. Touching it may cause burns.
Leave the drive unit to cool before assembly.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 41
Assembly
4Tighten the securing screw with a 5 mm
hexagon socket spanner to 5-6 Nm.
The lever is mounted.
Figure 31: Tightening the securing screw
5.4.1.2 Screw-on axle (20 mm)
Only applies to Suntour forks with 20 mm screw-on axle
1Insert the axle completely on the drive side.
Figure 32: Tightening the inserted axle
2Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 33: Tightening the securing clip
5.4.1.3 Quick release axle
Only applies to Suntour forks with screw-on axle
1Insert the axle into the hub on the drive side.
Figure 34: Pushing the axle into the hub
Crash caused by loose quick release axle
A faulty or incorrectly installed quick release axle
may become caught in the brake disc and block
the wheel. This will cause a crash.
Never fit a defective quick release axle.
Crash caused by faulty or incorrectly
installed quick release axle
The brake disc becomes very hot during
operation. Parts of the quick release axle may
become damaged as a result. The quick release
axle becomes loose. This will cause a crash with
injuries.
The quick release axle and the brake disc
must be opposite one another.
Crash caused by incorrectly set quick release
axle
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release axle may
break. This will cause a crash with injuries.
Never fasten a quick release axle with a tool,
such as a hammer or pliers.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 43
Assembly
5.4.1.4 Quick release
Only applies to Suntour forks with quick release
1Before installing, ensure that the quick release
flange is extended. Open the lever fully.
Figure 40: Open and closed flange
2Push in the quick release until you can hear a
click. Make sure that the flange is extended.
Figure 41: Pushing the quick release in
3Adjust tensioning with half-open clamping
lever until the flange reaches the fork end.
Figure 42: Adjusting the clamping
4Fully close the quick release. Check that the
quick release is firmly in place and adjust it on
the flange if necessary.
The lever is secured.
Figure 43: Closing the quick release
Crash caused by unfastened quick release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Never fit a defective quick release.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. The
suspension fork or the quick release may break.
This will cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 45
Assembly
5.4.2.2 Kabolt axle
Only applies to FOX forks with Kabolt axles
The same procedure is used for installing both the
15 x 100 mm and 15 x 110 mm Kabolt axles.
1Place the front wheel in the fork ends of the
fork. Push the Kabolt axle through the fork end
on the non-drive side and hub.
Figure 47: Pushing the Kabolt axle in
2Tighten the Kabolt axle screw to 17 Nm
(150 in-lb) with a 6 mm hex key.
5.4.3 Checking the stem and handlebars
5.4.3.1 Checking the connections
1Stand in front of the pedelec to check whether
the handlebars, stem and fork steerer are firmly
attached to one another. Clamp the front wheel
between your legs. Grasp the handlebar grips.
2Try to twist the handlebars towards the front
wheel.
The stem must not move or twist.
5.4.3.2 Firm hold
1Place your entire body weight on the
handlebars with the quick release lever closed
to check that the stem is firmly in place.
The handlebars shaft must not move
downwards in the fork steerer.
2If the handlebars shaft should move in the fork
steerer, increase the quick release lever
tensioning. To do so, turn the knurled nut
slightly in a clockwise direction with the quick
release lever open.
3Close the lever and check the stem is firmly in
position.
5.4.3.3 Checking the headset backlash
1To check the handlebar headset backlash,
close the quick release lever on the stem.
2Place the fingers of one hand on the upper
headset cup. Pull the front wheel brake with the
other hand and try to push the pedelec
backwards and forwards.
3The headset cup halves must not move
towards one another while you are doing this.
Note that there may be noticeable backlash
due to worn-out bearing bushes or brake lining
backlash in suspension forks and disc brakes.
4If there is headset backlash in the steering
headset, you must adjust it as soon as
possible; otherwise, the headset will become
damaged. You must make the adjustment as
described in the stem manual.
5.5 Pedelec sale
Complete Pedelec pass on the operating
instructions envelope.
Note down the battery key manufacturer and
its number.
Adjust the pedelec to the rider; see Section 6.5.
Set the stand and shifter.
Instruct the operator or rider on how to use all
the pedelec's functions.
MY21B01 - 12_1.0_25.06.2020 46
Operation
6 Operation
6.1 Risks and hazards
Injuries and death caused by other road users
Other road users, trucks, cars or pedestrians often
underestimate the speed of pedelecs. Likewise,
other road users frequently do not see pedelecs.
This may cause a crash with serious injuries or
even death.
Wear a cycling helmet and high-visibility,
reflective clothing.
Always take a defensive approach to riding.
Avoid the blind spots of vehicles turning off.
Reduce speed as a precaution when other
road users turn right.
Injuries and death caused by riding
incorrectly
A pedelec is not a bicycle. Incorrect riding and
underestimated speeds soon result in hazardous
situations. This may cause a fall with serious
injuries or even death.
If you haven't ridden on a pedelec for some
time, get accustomed to the speed first before
you ride at speeds over 12 km/h. Increase the
level of assistance gradually.
Practice braking hard on a regular basis.
Take and complete a riding safety course.
Crash caused by loose clothing
Shoe laces, scarves and other loose items may
become entangled in the spokes on the wheels
and on the chain drive. This may cause a crash
with injuries.
Wear sturdy footwear and close-fitting
clothing.
WARNING
!
CAUTION
!
Crash caused by difficult-to-spot damage
If the pedelec topples over or you have a fall or an
accident, there may be difficult-to-spot damage to
components such as the brake system, quick
releases or frame. This may cause a crash with
injuries.
Take the pedelec out of service and have a
specialist dealer carry out an inspection.
Crash caused by material fatigue
Intensive use can cause material fatigue. A
component may suddenly fail in case of material
fatigue. This may cause a crash with injuries.
Remove the pedelec from service immediately
if there are any signs of material fatigue. Have
the specialist dealer check the state.
Have the specialist dealer carry out a basic
inspection regularly. During the inspection, the
specialist dealer will inspect the pedelec for
any signs of material fatigue on the frame,
fork, suspension element mountings (if there
are any) and components made of composite
materials.
Carbon becomes brittle when exposed to heat
radiation such as heating. This can cause the
carbon part to break and result in a crash with
injuries.
Never expose carbon parts on the pedelec to
strong sources of heat.
Crash caused by soiling
Heavy soiling can impair pedelec functions, such
as braking. This may cause a crash with injuries.
Remove coarse soiling before riding.
CAUTION
!
MY21B01 - 12_1.0_06.07.2020 50
Operation
6.3.2 Rechargeable battery
The battery is protected against deep discharge,
overcharging, overheating and short circuits by
Electronic Cell Protection (ECP). In the event of a
hazard, a protective circuit switches the battery off
automatically.
If a fault is detected in the battery, the LEDs flash
on the battery level indicator.
840 Internal ABS error Contact your specialist
dealer.
850 Internal ABS error Contact your specialist
dealer.
860, 861 Error in the power supply 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
870, 871,
880
883..
885
Communication error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
889 Internal ABS error Contact your specialist
dealer.
890 ABS indicator lamp is
defective or missing; ABS
possibly not functioning
Contact your specialist
dealer.
No
screen
display
Internal display error Re-start the drive system by
switching it on and off.
Code Description Method of resolution
Table 47: List of display screen error messages
Code Description Method of resolution
If the battery is outside its
charging temperature
range, three LEDs will
flash on the battery level
indicator.
1Disconnect charger from
battery.
2Leave battery to cool down.
3Contact your specialist
dealer if the problem
persists.
If a fault is detected in the
battery, two LEDs flash on
the battery level indicator.
Contact your specialist
dealer.
No LEDs will flash if the
charger is defective and
will not charge. One or
more LEDs will light up
permanently, depending
on the battery level.
Contact your specialist
dealer.
No LEDs will light up if
there is no power. 1Check all plug connections.
2Check the contacts on the
battery for dirt. Clean the
contacts carefully if needed.
3Contact your specialist
dealer if the problem
persists.
Table 48: List of battery error messages
2

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