Bion x D-series User manual

USER MANUAL

GUIDE D’UTILISATION

BENUTZERINFORMATION

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Welcome

Thank you for choosing BionX™. It is our goal to provide you with the highest quality electric

propulsion systems available, and offer you the best possible after sales experience. 

This document serves as a supplement to your bicycle user manual. Please read this manual

thoroughly, even if you are an experienced cyclist. Should you be unable to ﬁnd an answer in

the manual, please contact your dealer for immediate assistance. 

We have always believed that a bike should remain a bike. It is our love of cycling that drives

us, and a passion that we continue to share with our customers. We hope you enjoy your

new electrically assisted bicycle for many years to come.

If you ever have concerns or questions that your dealer cannot provide answers to, or have

comments relating to this user manual, feel free to contact us in Europe at service.eu@

ridebionx.com, in North America at [email protected], and anywhere else in

the world at [email protected]

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Table of Contents

User Precautions 4

Description of the BionX D-Series System 6

Description of the BionX S-Series System 8

Description of the BionX P-Series System 10

Inserting or Removing the DS3 Display 12

Inserting or Removing the Console 13

Inserting or Removing the Battery 14

Handling and Charging the Battery 15

Power Supply 17

Assist Mode / Generate Mode / Mountain Mode

(where applicable) 18

Operating the BionX Propulsion System 19

Programming the Basic Settings 24

Removing and Installing the Rear Wheel 25

Maintenance and Care 26

Optimizing the Range of the Battery 27

Cleaning 28

Transporting an Electric Bicycle 28

Repair and Spare Parts 28

Troubleshooting 29

Warranty Information and Guarantee 30

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. Take the opportunity to familiarize yourself with your

BionX electric propulsion system before you take your ﬁrst trip.

1. BionX recommends that you have your system installed professionally by an authorized dealer. 

2. Read all of the enclosed installation and operating instructions from the manufacturer

and follow the instructions, if any, prior to its ﬁrst use.

3. 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.

4. Always wear a helmet when riding an electric bicycle for your own safety. In some jurisdictions,

this is the law.

5. Make sure that the tires have the pressure recommended by the manufacturer before riding the bike.

6. Make sure that the brakes are operating properly 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.

Enjoy your new BionX electric propulsion system!

Your BionX Team

NOTE

The parts shown in the BionX User Manual are for reference only, the parts included with

your BionX system may differ from those shown. More detailed information can be ob-

tained from your BionX dealer by request.

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Description of the BionX D-Series System 3D-Series Motor

• DC rear hub motor

• Power – (nom.) 200W (AU & UK), 250W (EU), 500W

(NA)

• Torque – (nom./max.) 25Nm/50Nm (18.4/37lb-ft)

• Weight – 4.0kg (8.8lb)

• Brushless, gearless

• Generate mode for energy recuperation

• Integrated torque sensor

• 8, 9, and 10 speed cassette compatible

4Brake switch

• A surface mounted reed switch and magnet –

connected to the BionX console

• Upon brake application, assistance is shut off

(“kill switch”) and Generate mode is activated

Power Supply

• Power supply to recharge the 48V Li-Ion battery

• Input voltage: 100-240V

• Output voltage: 26V

• Max. charge current: 3.45A

• Output: 90W

1RC3 Controller and (optional) DS3 Display

• Removable colour DS3 display console

• 4 Assistance levels

• 4 Generate levels

• RC3 with system controls, battery state-of-charge

indicator

• Offers cyclecomputer functions (speed, odometer,

clock, average speed, trip distance)

G2 Console

• Removable G2 console

• Illuminated LCD display with battery state-of-charge

• 4 Assistance levels

• 4 Generate levels

• Backlight, and bicycle light controls (if applicable)

• Offers cycle computer functions (speed, odometer,

clock, average speed, trip distance)

Remote throttle (where applicable)

• Assistance/Generate toggle

• Variable control throttle lever

248V Down Tube Battery

• Lithium Ion (Li-Ion)

• Removable, lockable

• TOUCH PORT state-of-charge indicator

• DV – 48V / 11.6Ah / 555Wh

• DC Output: Default 6V (adjustable from 6V to 12V

where applicable). Maximum current: 1.5A

Connector: Type Jack 2.1mm

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Description of the BionX S-Series System

3S-Series Motor

• DC rear, high torque (HT) hub motor

• Power – (nom.) 200W (AU & UK), 250W (EU), 350W

(NA)

• Torque – (nom./max.) 9Nm/40Nm (6.6/29lb-ft)

• Weight – 3.5kg (7.7lb)

• Brushless, gearless

• Generate mode for energy recuperation

• Integrated torque sensor

• 8, 9, and 10 speed cassette compatible (NA only,

where available)

4Brake switch

• A surface mounted reed switch and magnet –

connected to the BionX console

• Upon brake application, assistance is shut off

(“kill switch”) and Generate mode is activated

Power Supply

• Power supply to recharge the 48V Li-Ion battery

• Input voltage: 100-240V

• Output voltage: 26V

• Max. charge current: 3.45A

• Output: 90W

1G2 Console

• Removable G2 console

• Illuminated LCD display with battery state-of-charge

• 4 Assistance levels

• 4 Generate levels

• Backlight, and bicycle light controls (if applicable)

• Offers cycle computer functions (speed, odometer,

clock, average speed, trip distance)

Remote throttle (where applicable)

• Assistance/Generate toggle

• Variable control throttle lever

2a 48V Down Tube Battery

• Lithium Ion (Li-Ion)

• Removable, lockable

• TOUCH PORT state-of-charge indicator

• DV - 48V / 11.6Ah / 555Wh

• DX – 48V / 8.8Ah / 423Wh

• DL – 48V / 6.6Ah / 317Wh

• DC Output: Default 6V (adjustable from 6V to 12V

where applicable). Maximum current: 1.5A

Connector: Type Jack 2.1mm

2b 48V Rear Rack Battery

• Lithium Ion (Li-Ion)

• Removable, lockable

• TOUCH PORT state-of-charge indicator

• RX - 48V / 8.8Ah / 423Wh

• RL - 48V / 6.6Ah / 317Wh

• DC Output: Default 6V (adjustable from 6V to 12V

where applicable). Maximum current: 1.5A

Connector: Type Jack 2.1mm

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Description of the BionX P-Series System

1G2 Console

• Removable G2 console

• Illuminated LCD display with battery state-of-charge

• 4 Assistance levels

• 4 Generate levels

• Backlight, and bicycle light controls (if applicable)

• Offers cycle computer functions (speed, odometer,

clock, average speed, trip distance)

Remote throttle (where applicable)

• Assistance/Generate toggle

• Variable control throttle lever

2a 48V Down Tube Battery

• Lithium Ion (Li-Ion)

• Removable, lockable

• DV - 48V / 11.6Ah / 555Wh

• DX - 48V / 8.8Ah / 423Wh

• DL - 48V / 6.6Ah / 317Wh

• DC Output: Default 6V (adjustable from 6V to 12V

where applicable). Maximum current: 1.5A

Connector: Type Jack 2.1mm

2b 48V Rear Rack Battery

• Lithium Ion (Li-Ion)

• Removable, lockable

• RX - 48V / 8.8Ah / 423Wh

• RL - 48V / 6.6Ah / 317Wh

• DC Output: Default 6V (adjustable from 6V to 12V

where applicable). Maximum current: 1.5A

Connector: Type Jack 2.1mm

3250, 250HT, 350HT, or 500HS* P-Series Motor

• DC rear hub motor

• 250: nom. output 200 (AU & UK) or 250 watt –

nom. 7Nm / max. 25Nm (5.2/18.4 lb-ft) torque

• 250HT / 350HT: nom. output 200 (AU & UK),

250 (EU), 350 (NA) watts – nom. 10Nm / max. 40Nm

(7.4/29.5lb-ft) torque

• 500: nom. 500 watt – nom. 9Nm / max. 25Nm

(6.6/18.4lb-ft) torque

• Weight - 4.7kg (10.4lb)

• Brushless, gearless, with integrated torque sensor

• Generate mode for energy recuperation

• 8, 9, and 10 speed cassette compatible

4Brake switch

• A surface mounted reed switch and magnet –

connected to the BionX console

• Upon brake application assistance is shut off

(“kill switch”) and Generate mode is activated

Power Supply

• Power supply to recharge the 48V Li-Ion battery

• Input voltage: 100-240V

• Output voltage: 26V

• Max. charge current: 3.45A

• Output: 90W

*Note: the 500 watt motor is not legal in all jurisdictions. Check with your local BionX dealer for local legislation and/or availability.

ELECTRIC SERIES

ODO

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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 a “click”

Removing the console

• Release the console by pushing the release lever on the console mount

• Slide the console out of the console mount

Center mount

• Available option for all BionX systems

• To be used with regular receptacle, replaces standard mounting

kit (clip & rubber)

“click”

WARNING

Never unplug any connection with the system turned on - this includes the console. Pulling

a live part can render it inoperable!

Inserting or Removing the DS3 Display

Inserting the DS3

• Turn the system off via the RC3 controller (no illustration)

• Place the DS3 on the display dock turned 90° to the left

• Rotate the DS3 90° to the right and the DS3 is locked in place

Removing the DS3

• Turn off the system via the RC3 controller (no illustration)

• Rotate the DS3 90° to the left, it will pop loose

• Lift the DS3 up to remove

WARNING

Never unplug any connection with the system turned on - this includes the DS3 display.

Pulling a live part can render it inoperable!

CLICK

ODOMETER

1234.5 km

km/h

ODOMETER

1234.5 km

km/h

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Inserting the rear rack battery:

1Open the lock cylinder: please ensure that the key is removed from the lock cylinder

2Place the battery onto the battery docking station

3Gently push the battery in a forward direction, towards the battery connector

Make sure the battery is inserted all the way, ﬂush with the docking station cover

4Push in the lock cylinder until a ‘click’ is heard

Removing of the rear rack battery:

1Turn off the system via the console (no illustration)

2Turn the key in the lock cylinder until it pops out

3Remove the key from the lock cylinder

4Pull the battery backwards, along the battery rail

Handling and Charging the Battery

WARNING

BionX batteries shall only be recharged with BionX chargers or BionX power supplies. The

use of other power supplies/chargers can damage the battery. Never short circuit the bat-

tery by connecting the contacts of the battery. Never open the battery, as this could dam-

age the battery and possibly lead to overheating. 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 case(s) or the battery connector.

001

WARNING

Do not force the battery onto the battery docking station. This can damage the battery

connector, or damage the rear light. Never unplug any connection with the system turned

on - this includes the battery. Pulling a live part can render it inoperable! If a battery is re-

moved while the system is turned on, wait 5 minutes until it turns off before re-installing.

A series of 5 beeps will indicate the battery has shut off and it is safe to install again.

001

1” (25.4mm)

001

CLICK

Inserting or Removing the Battery

Inserting the down tube battery

1Place the battery onto the docking station

2Slide the battery down the rail gently towards the connector

3The release arm will begin to move to the closed position as the battery slides towards the connector

4When the release arm is almost closed, hold it in place and simultaneously push in the lock cylinder –

you will hear a “click” when the lock cylinder is properly closed

Removing the down tube battery

1Turn off the BionX propulsion system via the console (no illustration)

2Lightly press on the battery release arm, insert the key and turn clockwise

The lock cylinder will pop out, freeing the battery release arm

3Remove the battery by opening the release arm

4Slide the battery upwards on the rail

5Lift the battery to remove

25.4mm (1”)

001

25.4mm (1”)

001

1” (25.4mm)

001

WARNING

Do not force the battery release arm closed, or force the battery onto the battery dock.

This can damage the battery connector. Never unplug any connection with the system

turned on - this includes the battery. Pulling a live part can render it inoperable! If a bat-

tery is removed while the system is turned on, wait 5 minutes until it turns off before re-

installing. A series of 5 beeps will indicate the battery has shut off and it is safe to install

again.

25.4mm (1”)

001

25.4mm (1”)

001

25.4mm (1”)

001

1” (25.4mm)

001

“click”

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Power Supply

48V battery charging procedure (power supply)

• Connect the power supply and the battery by

inserting the charge connector into the TOUCH PORT

– the BionX system can be on or off

• Connect the power supply to a power receptacle

• The battery TOUCH PORT (LED ring around the

charge connector) lights up red upon insertion and

then turns to amber during the charging process

• When fully charged, the colour of the LED ring

changes to green. The battery charging process is

then complete

• Following this procedure the charging connector should be disconnected from the battery

• During the charging process you can check the battery state-of-charge through the console if the

battery is connected to the system – a 48V system can be switched on while it is charging

This has my vote :)

Battery state-of-charge Colour

100-75 % Green

75-20 % Amber

< 20 % Red

Checking the 48V Battery state-of-charge

• Swipe your ﬁnger slowly over the TOUCH PORT

• Battery state-of-charge LED will illuminate

• Allow ten (10) seconds before checking state-of-charge again

NOTE

The power supply is suitable for line voltage ranges of 110-115V or 220-230V, and com-

pensates automatically. The 48V battery is designed to be charged by a 26V BionX power

supply. The battery has an integrated charger which permits the use of a small, portable

power supply.

Ensure that a completely charged battery is no longer connected to the power supply after the charge

procedure is completed.

TOUCH PORT green =

fully charged

TOUCH PORT amber =

charging

TOUCH PORT red =

upon insertion

It is best to store the battery in a cool location at temperatures between 10 °C (50 °F) and 25 °C (77 °F).

Never store the battery in locations where the temperatures can reach more than 45 °C (113° F) or

fall below -10 °C (14 °F). The battery should never be exposed to extreme temperature ﬂuctuations

or humidity, and always protect the battery during storage from humidity to prevent corrosion of the

connectors. Never drop the battery. Always protect it from physical damage. Damage may lead to short-

circuits, and as a result cause overheating of the battery.

Do not dispose of used batteries in regular household trash, be aware that used batteries

must be disposed of properly! BionX batteries can be returned to BionX to be recycled.

WARNING

The BionX power supply/charger should be used exclusively for BionX rechargeable

batteries of the speciﬁed type. Keep the power supply or charger away from water or

moisture when charging and/or connected to prevent electrical shock or short-circuits.

Do not use a power supply or charger that has obvious signs of damage to the cable,

housing, or the connector.

Extreme temperatures will affect battery life, especially during charging. Avoid charging in direct sunlight

or in very hot or cold temperatures as this will reduce the life of the battery considerably. We recommend

charging the battery at room temperature (approximately 20 °C / 68 °F). The battery should be warmed to

room temperature before it is charged, particularly if it was exposed to cold temperatures during a ride.

The battery can be charged when mounted on the bicycle or removed from the docking station.

A Lithium Ion 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 state-of-charge display shows less than 50%. When the battery is fully depleted it will

signal that a recharge is needed by beeping. The battery is fully charged after approximately 4 to 5.5 hours.

CAUTION

All classic BionX batteries must be charged when not in use for a long period of time (i.e.

before winter storage) and then must be charged at minimum every three months. Not

charging the battery can lead to potential damage of the battery cells. This is a lack of

maintenance on behalf of the owner, which can incur a loss of warranty.

NOTE

New 48V BionX batteries are equipped with “Deep Sleep” mode, a function that preserves battery

energy depending on either the state of charge or signiﬁcant inactivity. A fully charged battery will

automatically enter Deep Sleep after 2 months, while a partially discharged battery will enter it in

increasingly faster time frames. This results in minimal energy consumption during standby and enables

a shelf life of up to 6 months for a fully discharged battery, and up to 18 months for a fully charged

battery. To activate a battery that has entered Deep Sleep mode, connect it to the 26V BionX power

supply and allow it to complete a full charge cycle. BionX still recommends charging these batteries at

minimum every 6 months.

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Assist Mode / Generate Mode / Mountain Mode (where applicable)

The BionX propulsion system offers four levels of assist in the Assistance mode, and four levels of

regeneration in the Generate mode. In the Assistance mode, your pedaling is assisted proportionally by

an electric motor that drives the rear wheel. A torque sensor is located on the axle of the BionX motor

and measures the effort provided by the rider; this produces a natural feeling assistance from the motor.

A cadence of roughly 80 RPM is ideal, this allows for effective response from the torque sensor and

efﬁcient use of battery energy.

When in Generate mode, the BionX 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 level of braking, however it does not replace legally required brakes. If the rear brake lever is

pulled, the drive system automatically enters Generate mode. The range can therefore be extended up to

15%, depending upon road conditions.

The Mountain mode uses an intelligent algorithm based upon the effort and the assistance level required.

The Mountain mode provides the rider with an assistance level optimized for climbing long steep hills.

Without this mode, the motor can automatically revert to an overheat protection mode thereby diminish-

ing the assistance provided. Note that level 4 assist is more powerful than Mountain mode.

NOTE

It is recommended that the BionX system should always be turned ON while riding.

It allows the rider to use the regenerative braking feature, speedometer and odometer

functions. A rider should always remain in control and adjust their speed depending on ter-

rain, riding conditions, and their own skill level.

250HT (EU) / 350HT (NA) / D-Series Motor performance

Assistance Mode (A) Level of Assist Riding Situation

135% Riding on level ground

275% Slight inclines, head wind

3150% Steep hills, strong head wind

4300% Very steep roads

250/500 Motor performance

Assistance Mode (A) Level of Assist Riding Situation

125% Riding on level ground

250% Slight inclines, head wind

3100% Steep hills, strong head wind

4200% Very steep roads

Mountain Mode (where available) Long, steep climbs

Generation Mode (G)

1Slight downhill grade, tailwind

2Signiﬁcant downhill grade, tailwind

3Steep descent

4Very steep descent

Turn the system on

Brieﬂy push , the battery will beep 4times and the bat-

tery LEDs will illuminate. After startup, the system is always

in Neutral (N / green LED) mode, indicating no motor

assist/normal bicycle operation. To turn the system off, hold

for 4 seconds and the battery will beep 5 times. After 5

minutes of inactivity the system turns off automatically.

Operating the BionX Propulsion System

RC3 Controller

1. On/Off button

2. Lights on/off

3. Battery state-of-charge indicator

4. Neutral/Assist/Generate level

5. Assistance toggle (+)

6. Left toggle / Select (with DS3 only)

7. Right toggle / Scroll (with DS3 only)

8. Assistance toggle (-)

9. Throttle lever

ODOMETER

1234.5

km/h

ODOMETER

1234.5 km

km/h

Select Assistance/Generate level

Push / key for more/less assist (see LEDs 1-4 along left hand side of module). From Neutral (N) push

key to enter continuous Generate mode - the LEDs will ﬂash to indicate Generate mode.

Turn on bicycle light (if applicable)

Brieﬂy push key bicycle lights (if available, battery integrated) are turned on.

Turn off bicycle light

Brieﬂy push key again.

Throttle engagement

Default min. 3km/h to engage throttle. Note: throttle control is variable based on lever position.

WARNING

Both the RC3 and G2 throttle should be installed in a manner/location where shift lever,

brake lever or any other accessory does not at any time affect the proper function and use

of the throttle.

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Operating the BionX Propulsion System

Turn the system on

Brieﬂy push either top button on the console. The

battery will beep 4times 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, brieﬂy push .

The battery will beep 5 times. After 5 minutes of “no

operation” the system turns off automatically.

Select Assistance/Generate level

Push / key for more/less assist (see bar “ﬁelds 1-4”

above display “A”). From mode push key to

enter continuous Generate mode.

4 3

1. Power

2. Key

3. Key

4. Cycle

5. State-of-charge

indicator

6. (bicycle) mode

7. Speedometer

8. Trip distance/average speed/

chronometer/odometer/clock

9. Assist level (A)

10. Generate level (G)

11. Wrench symbol

G2 Console

NOTE

The system performs a self check approximately every hour. Do not be alarmed if the

system turns itself on brieﬂy, and off again, or if the TOUCH PORT ﬂashes momentarily.

Operating the DS3 Display with the RC3 Controller

The DS3 screens shown may vary slightly depending on which version you have selected to

view.

ODOMETER

1234.5 km

km/h

ODOMETER

1234.5

TRIP

0.5

1. Assist / Generate level indicator

2. Light indicator

3. Power / Generate meter

4. Speedometer

5. Battery state-of-charge indicator

6. Cyclecomputer function

Select Assistance/Generate level

Push / buttons on the RC3 to adjust assistance /

generate levels. From Neutral (N, green LED) push

key to enter continuous Generate mode.

Toggle Cyclecomputer Functions

Brieﬂy push left and right toggle to display Odom-

eter, Trip Distance, Trip Time, Average Speed, Clock

and Settings. To reset Trip Distance, Trip Time,

and Average Speed, press and hold the left toggle

(Select) for 3 seconds.

Toggle Display Screen Type

Hold right toggle (Scroll) for 3 seconds to alternate

display between Simple, Enhanced, or Technical

screens. The default screen at startup can be altered

in the Settings Menu.

ODOMETER

1234.5 km

km/h

ODOMETER

1234.5

TRIP

0.5

ODOMETER

1234.5 km

km/h

ODOMETER

1234.5

TRIP

0.5

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Turn on backlight and bicycle light (if applicable)

Push and hold key for 4 seconds - display backlight

and bicycle light (if available, battery integrated) are

turned on.

Turn off backlight

Push and hold key again for 4 seconds.

Select the cycling computer functions

Brieﬂy push the key to change between:

Trip Distance DIST

Odometer ODO

Clock CLOCK

Average Speed AVSPD

Chronometer CHRONO

To reset the cycle computer functions

Hold the key for a few seconds to reset the distance,

chronometer, or average speed values to zero.

WARNING

If this symbol appears please contact your BionX dealer for service.

Mountain Mode (where available)

Hold the button from any level of (A) or (G) to

engage. The four assist levels will ﬂash, MOUNTAIN

will appear brieﬂy. Press to disengage.

Operating the G2 Throttle

Throttle engagement:

Default min. 3km/h to engage throttle

Note: throttle control is variable, and the force

gauge on the console reacts proportionally. The

throttle function and assist modes are

independent to each other.

Assistance levels 1-4:

From press for more assist

or for less assist

Generation 1-4:

From press for more resistance

or for less resistance

NOTE

The G2 throttle is only compatible with the G2 console, and may not be available in all

jurisdictions. Check with your local BionX dealer for local legislation and/or availability.

G1 Console For the G1 console, substitute mode for power, and

crono for cycle. The assistance toggle remains the same.

G1 G2

Mode/Power becomes Power

Crono becomes Cycle

Remains the same

If you require more information on the G1 console,

please contact your dealer.

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24 25

Programming the Basic Settings

In general, all settings of your BionX electric propulsion system are pre-set. Basic display functions can

be set by entering the programming mode. Contact your dealer to customize the advanced functions of

your system.

Go to the Settings screen for the DS3 Display/RC3 Controller

Scroll through the cyclecomputer functions with the left or right toggle buttons until the display shows

“Settings”. Cycle the menus / values with or and conﬁrm with the left toggle (Select) button. Move

back a menu with the right toggle (Scroll) button.

Turn on the programming mode for the G2 console

Simultaneously push and until the display shows “0000”. The ﬁrst zero blinks. Change the value

of the selection with or and conﬁrm with . Select the other digits in the same manner until the

desired program is displayed.

Note: For G1 programming, substitute (mode) and (crono) for (power) and (cycle)

respectively, and remain the same.

Code Description

2001 Select km/h or mph

2002 Regeneration/brake output (for reed switch) 0-40 (ideally 30-40)

2004 Clock adjust

2005 Tire circumference (millimeters)

2009 Flip Display: 0 = power left, 1 = power right (G2 only)

Code 2001 Code 2002 Code 2004

Select unit - km/h or mph. Select with

or , and conﬁrm with .

Default value: 30. Change with

and . Conﬁrm with . Select hour/minutes with ,

change value with and .

Conﬁrm with .

Code 2005 Code 2009

Set tire size (in mm) - Select digits

one after another with or , and

conﬁrm with .

Current setting of main functions is displayed. Flip = 0, assist toggle is

the right side of console; Flip = 1,

assist toggle is on the left side of console.

Conﬁrm with .

WARNING

Do not use other programming codes without consulting your authorized dealer.

If you type the wrong code, please push the key to exit programming mode.

Removing and Installing the Rear Wheel

We recommend 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:

To remove the rear wheel

1Make sure that the system is turned off via the console (no illustration)

2Remove the neoprene covers (if applicable)

3Disconnect the two cable connections that lead to the motor (COMMUNICATION A, before POWER B)

4Disconnect the cable guide from the rear wheel brake (only on bicycles with rim brakes, not shown)

5Loosen the axle nut on the rear wheel using a 15mm wrench

6Slide the rear wheel downwards, out of the dropout

WARNING

Always turn off the propulsion system prior to connecting or disconnecting the motor

cables.

CAUTION

It is essential that the axle nuts are tightened to 40Nm (30lb-ft); this assures that the

propulsion system functions properly. Ensure the torque reaction collar is fully inserted

into the dropout. The notch on the non-drive side must also be facing in the direction of

6 o’clock (within 5° either way). If this notch placement is incorrect, please consult your

dealer.

If your bike is equipped with hydraulic disc brakes: 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 the brake disc from sliding in place.

15mm

40Nm

(30lb-ft)

15mm

40Nm

(30lb-ft)

40Nm

15mm

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26 27

Installing the rear wheel

1Guide the rear wheel axle into the dropouts and ensure that the brake disc (on models with disc

brakes) is inserted between the brake pads. Ensure that the torque reaction collar is aligned so that it

ﬁts into the left dropout (no illustration). Make sure the axle is inserted all the way into the dropouts

2Tighten the axle nuts to 40Nm (30lb-ft) (= VERY TIGHT!). This torque is essential for the correct func-

tion of the propulsion system. If you do not have a torque wrench, use a normal wrench, and then

have your dealer check the torque of the axle nuts as soon as possible. Use only the original axle nuts;

otherwise you run the risk of damaging the axle threads

3Connect the cables (POWER Abefore COMMUNICATION B)

4Keep the motor cables clear of the brake disc (on models with disc brakes) and the motor casing

5Re-install the cable of the rear wheel brake (rim brakes only), and correctly adjust the rear wheel brake

(no illustration)

6Place the larger neoprene cover over the plug-in connections, and the smaller neoprene cover closer to

the disc/motor to prevent the cables from contacting any moving portions of the motor

ODOMETER

1234.5 km

km/h

ODOMETER

1234.5

TRIP

0.5

Installing the rear wheel with 142mm axle

A D-Series motor with 142mm axle is supplied with 2

bolts in place of the standard axle nuts.

The speciﬁed torque is 20Nm (15lb-ft).

Maintenance and Care

We recommend to have the spoke tension of the rear wheel and the torque of all screws checked by a

qualiﬁed dealer after the ﬁrst 200km (125 miles).

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 BionX

motor does not require maintenance.

15mm

40Nm

(30lb-ft)

15mm

40Nm

(30lb-ft)

15mm

40Nm

(30lb-ft)

Optimizing the Range of the Battery

The following factors inﬂuence the range of your battery:

1. Climbing

Riding up steep hills requires much more energy than riding on ﬂat ground. More effort, proper cadence,

and/or a change to a more gradual route can greatly affect overall range.

2. Level of assistance

Choose the level of assist required based on riding conditions, rather than just riding in one particular level

all the time. Remember that energy consumption more than doubles from level 2 assist to level 4. Limit

the use of the throttle as much as possible to reduce energy consumption.

3. Battery state of charge

Make sure the battery is fully charged before every ride. This will provide the best possible range from the

battery each time.

4. Weight and load capacity

A heavier bike (and rider) lowers the range of the battery. Every ounce counts! Limit your cargo, think

about getting an efﬁcient type of bicycle for the system, even what type of gear you wear.

5. Tire pressure

Tires with pressure that is low will have increased rolling resistance, and require more energy from the

battery. It is important to regularly check your tire pressure, the max. pressure is typically written on the

sidewall of any tire. Slick, skinny, high pressure tires offer the most efﬁciency for you and your battery.

6. Acceleration and constant speed

It is important to ride efﬁciently; electric propulsion systems consume more energy when accelerating

from a stand still. Try to keep your speed constant and retain momentum, starts and stops greatly affect

your overall range.

7. Outside inﬂuences/weather

You will notice some difference in range when it is very hot or cold outside, this inﬂuences how quickly

the battery will discharge. Headwinds can also greatly affect system performance. Expect more range on

days with moderate climate.

8. Cadence and Shifting

Keeping your cadence high (between 80-90 rpm) is the most efﬁcient pedaling range for most cyclists. A

high pedaling rate in combination with the lowest level of assist will offer the most range, the more slowly

you pedal and the more you rely on the electric assist, the less range you will get. Use your shifters to ride

efﬁciently, just as you would with any other bicycle!

CAUTION

It is essential that the axle bolts are tight-

ened to 20Nm (15lb-ft); this assures that the

propulsion system functions properly.

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28 29

Cleaning

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

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 using the bicycle.

Transporting an Electric Bicycle

WARNING

Make absolutely certain 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 electric bicycle. The electric bicycle can

be damaged by an unsuitable bike rack.

When transporting a BionX equipped bicycle on a bike rack, always remove the battery and the console.

In case of inclement weather, your motor and system connections should be protected from the elements.

When travelling by air, it is important to understand that a lithium battery is classiﬁed as dangerous goods

and must be transported by a qualiﬁed handler. Your battery cannot accompany you and your bicycle on

a commercial ﬂight.

Repair and Spare Parts

WARNING

The use of spare parts from unknown sources, for example replacement parts from third

parties, as well as opening the battery or replacing the cellpack is strictly prohibited.

For repair of your electric bicycle, consult a qualiﬁed dealer. The use of spare parts from unknown sources,

for example, replacement parts from third parties, is strictly prohibited. If you

need spare keys for the battery, please contact a BionX dealer. Please retain the

key number for your records. It is located on the battery key, as well as on the

face of the battery lock cylinder. If you are dropping off your bicycle for a

tune up or repair, always bring your battery keys to the dealer.

BionX Key Number

115

FUSE

This notch is very important

Troubleshooting

The system does not turn on

Check the battery and make sure that it is charged. The battery must be correctly inserted onto the

docking station and the lock must be completely closed. Also check that all connectors of the wiring

harness are properly engaged, and the console is inserted properly. If the problem persists, contact

an authorized dealer.

The system can be turned on but there is no assist / POWER PROT appears on console screen /

RC3 Controller LED lights are cascading

Check all connections, in particular that the cables running from the battery to the motor are properly

connected (with the system turned off). Turn the system on. If the problem persists, contact your 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 switch that is located under the brake lever.

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 switch you also disable regenerative braking, in doing so your

BionX system will not provide any additional braking. We recommend that you contact

a dealer as soon as possible.

The motor is not as powerful after a repair or service

Tighten the nuts of the rear axle to the speciﬁed torque (40Nm/30lb-ft); check that the axle slot is facing

in the direction of 6 o’clock. If the problem persists, contact an authorized 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 charge it again. If the gauge still does not indicate a full charge, let the battery cool

again, fully deplete the battery and charge it again. If the problem persists, contact an authorized dealer.

The throttle lever offers no response

Check the throttle connections. Next, attempt to calibrate the throttle, hold the and buttons

until a countdown begins at the top of the console screen. Fully depress the throttle lever and release

a few times during the countdown.

The system will not turn on after storage

48V BionX batteries are now equipped with “Deep Sleep” mode, a new function that preserves battery

energy. To activate a battery that has entered Deep Sleep mode, connect it to the 26V BionX power sup-

ply. If the battery is removed from the system when doing so, allow the battery 5 minutes until it turns off

before re-installing. A series of 5 beeps will indicate the battery has shut off and it is safe to install again.

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30 31

The console/display shows ACTIVATE IN XXkm or the green neutral LED on the RC3 is blinking

continuously

All new BionX systems are shipped in demo mode and require activation by an authorized dealer. If you

see this message or LED notiﬁcation, please return to your dealer so they can activate your system.

Warranty Information and Guarantee

The BionX warranty covers a two (2) year period for all parts of the BionX propulsion systems to

the ﬁrst owner within the framework of the following conditions:

1. This warranty exclusively covers systems provided by BionX excluding all the other bicycle components

provided by other bicycle manufacturers.

2. 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.

3. Any other legal provisions, particularly with respect to warranty regulations, are not restricted by this

warranty.

4. 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

serial number, the dealer’s name and the designation of the system model. BionX reserves the right to

reject the coverage of this warranty if the accompanying documentation of BionX components is not

accurate or complete.

5. 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).

6. 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 the dealer at the client’s own expenses and risks,

and, after the completion of such repair, has to be picked up at the dealer. 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.

7. 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.

8. Repair work and/or replacement of components during the warranty period does 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.

9. The two-year warranty period starts with the date of purchase. Warranty claims must be reported

immediately.

10. 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 within 500 charging cycles, whichever event occurs ﬁrst, to the condi-

tion that the battery provides less than 70% of its initial capacity.

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) Purposeful and/or malevolent acts, theft and robbery as well as natural hazard events and/or

acts of mischief.

c) 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“as

speciﬁed in the BionX User Manual

d) Overcharging the battery or not adhering to the instructions of battery handling.

e) Abuse/mis-handling of the connectors

f) In the case of malfunctioning internal and/or external components due to impact caused by drop-

ping a part on the ground.

g) If the motor axle nut has been over tightened / improperly installed to the point where the threads

of the axle have been damaged.

h) If the maximum weight on the bicycle (speciﬁcally – bicycle, rider, AND load) has been over 150kg.

i) If the functionality of the Touch Port feature is intermittent; this is a redundancy of the state of

charge indicator that is available on the console.

12. No warranty claims are accepted - without limitation to other reasons:

a) In the case of test, maintenance, repair and replacement work due to normal use.

b) If the model, serial or product number on BionX product has been changed, deleted, blurred or

removed. The seal and/or the serial number decal on the battery housing has been broken or

obviously manipulated.

c) In the case of use of the battery in systems that are not approved for such use with this particular

product.

d) In the case of the operation of the BionX system with batteries other than the batteries designed

for the BionX system (refer to user manual).

e) If one or more than one BionX part has been opened, altered or repainted.

f) The bike has been used for rental or commercial application.

13. 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.

14. This warranty only covers original BionX components. The use of spare parts from unknown sources,

for example, replacement parts from third parties, is strictly prohibited.

15. Warranty will be voided on any system on which it will be concluded that there has been any case of

modiﬁcation or tampering with ﬁrmware.

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32 33

BionX, BionX Design and powered by BionX are trademarks

of BionX International Corporation.

01-4646 EN REVISION C

16. One (1) additional year of warranty is provided free of charge on BionX systems starting from MY2016

if:

a) The bicycle has been registered on the date of purchase (or up to 90 days after system activation)

through the email link sent by BionX by providing the following requested information:

• Name

• Address

• Phone number

• Email

• Additional survey information

*** Please note that a false declaration will automatically void the extra year of warranty

b) The bicycle has been inspected and the software has been updated using the BBI at least once

every year (12 months) after the date of registration by an approved BionX dealer.

c) 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 offers

coverage within the three year warranty period or within 500 charging cycles, whichever event

occurs ﬁrst, to the condition that the battery provides less than 60% of its initial capacity.

d) Only the original system that is registered at the date of purchase is eligible for the 3 year

warranty.

e) the system is sold / activated within eighteen (18) months of the battery manufacturing date.

english

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