Bosch BULLS KIOX300 Wiring diagram

22-15-1069…22-15-1077, 22-15-1087…22-15-1089, 22-15-4007…22-15-4009
MY22B0a - 62_1.0_16.09.2021
CROSS LITE EVO 1, CROSS LITE EVO 2, CROSS MOVER EVO 3, CROSS RIDER EVO 2,
ICONIC EVO TR 1, ICONIC EVO TR 2
Translation of original operating instructions for
BULLS Pedelecs with BOSCH KIOX300 Display and
LCD Remote on-board computer
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE

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Contents
Contents
1 About these operating instructions
1.1 Manufacturer 10
1.2 Laws, standards and directives 10
1.3 Language 10
1.4 For your information 10
1.4.1 Warnings 10
1.4.2 Markups 10
1.5 Type number and model 11
1.6 Frame number 11
1.7 Identifying the operating instructions 11
1.8 Aim of the operating instructions 12
2 Safety
2.1 Residual risks 13
2.1.1 Risk of fire and explosion 13
2.1.1.1 Rechargeable battery 13
2.1.1.2 Overheated charger 13
2.1.1.3 Hot components 13
2.1.2 Electric shock 14
2.1.2.1 Damage 14
2.1.2.2 Water penetration 14
2.1.2.3 Condensation 14
2.1.3 Risk of a crash 14
2.1.3.1 Incorrect quick release setting 14
2.1.3.2 Incorrect tightening torque 14
2.1.3.3 Incorrect component 14
2.1.4 Risk of amputation 14
2.1.5 Key breaking off 14
2.1.6 Malfunctions due to Bluetooth® 15
2.1.7 Data privacy information 15
2.2 Toxic substances 16
2.2.1 Brake fluid 16
2.2.2 Defective battery 16
2.3 Requirements for the rider 16
2.4 Vulnerable groups 16
2.5 Personal protective equipment 16
2.6 Safety guards 16
2.7 Safety markings and safety instructions 17
2.8 What to do in an emergency 17
2.8.1 Dangerous situation in road traffic 17
2.8.2 Leaked brake fluid 17
2.8.3 Battery vapours emitted 18
2.8.4 Battery fire 18
3 Description
3.1 Proper use 19
3.1.1 Improper use 20
3.1.2 Permitted total weight (PTW) 21
3.1.3 Environmental requirements 22
3.2 Nameplate 24
3.3 Components 25
3.3.1 Overview 25
3.3.2 Chassis 26
3.3.2.1 Frame 26
3.3.2.2 Steering system 26

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Contents
3.3.2.3 Steering headset 26
3.3.2.4 Stem 26
3.3.2.5 Handlebars 27
3.3.2.6 Fork 27
3.3.3 Suspension 28
3.3.3.1 Rigid fork 28
3.3.3.2 Suspension fork 28
3.3.3.3 Rear frame damper 32
3.3.3.4 Suntour rear frame damper 34
3.3.4 Wheel 36
3.3.4.1 Tyres 36
3.3.4.2 Rim 36
3.3.4.3 Valve 36
3.3.4.4 Spoke 37
3.3.4.5 Spoke nipples 37
3.3.4.6 Hub 37
3.3.5 Braking system 38
3.3.5.1 Mechanical brake 38
3.3.5.2 Hydraulic brake 38
3.3.5.3 Disc brake 39
3.3.6 Seat post 40
3.3.6.1 Patent seat post 40
3.3.6.2 Suspension seat post 40
3.3.7 Mechanical drive system 41
3.3.7.1 Chain drive layout 41
3.3.7.2 Belt drive layout 41
3.3.8 Electric drive system 42
3.3.8.1 Motor 42
3.3.8.2 Rechargeable battery 42
3.3.8.3 Charger 43
3.3.8.4 Lighting 43
3.3.8.5 Integrated battery 43
3.3.9 On-board computer 44
3.3.9.1 Display 44
3.4 Description of controls and screens 45
3.4.1 Handlebars 45
3.4.2 Control panel 46
3.4.2.1 System message 47
3.4.2.2 Creating a user account 48
3.4.2.3 Software updates 48
3.4.2.4 Activity tracking 48
3.4.2.5 Lock function 48
3.4.3 Display 49
3.4.3.1 START SCREEN 49
3.4.3.2 Status screen 50
3.4.3.3 Settings 50
3.4.4 Battery level indicator (battery) 51
3.4.5 Gear shift 52
3.4.5.1 SHIMANO SW-E7000 derailleur gears 52
3.4.6 Hand brake 53
3.5 Technical data 54
3.5.1 Pedelec 54
3.5.2 Emissions 54
3.5.3 Bicycle lighting 54
3.5.4 Display mount 54
3.5.5 LED Remote on-board computer 54
3.5.6 BOSCH Kiox300 display 54
3.5.7 BOSCH Performance Line CX motor 54
3.5.8 BOSCH PowerTube 750 battery 55

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Contents
3.5.9 Tightening torques 56
4 Transporting and storing
4.1 Weight and dimensions for transportation 58
4.2 Designated handles, lifting points 58
4.3 Transportation 59
4.3.1 Using the transport securing system 59
4.3.2 Transporting the pedelec 59
4.3.3 Shipping a pedelec 59
4.3.4 Transporting the battery 59
4.3.5 Shipping the battery 59
4.4 Storing 60
4.4.1 Break in operation 60
4.4.1.1 Preparing a break in operation 60
4.4.1.2 Carrying out a break in operation 60
5 Assembly
5.1 Unpacking 61
5.2 Required tools 61
5.3 Commissioning 62
5.3.1 Checking the battery 62
5.3.1.1 Securing the PowerTube BS3 battery mount 63
5.3.2 Preparing the wheel 64
5.3.3 Installing the wheel in the SUNTOUR fork 65
5.3.3.1 Screw-on axle (12AH2 and 15AH2) 65
5.3.3.2 20 mm cross axle 66
5.3.3.3 Q-LOC quick release 68
5.3.4 Fitting the pedals 69
5.3.5 Preparing the LIMOTEC seat post 70
5.3.6 Checking the stem and handlebars 71
5.3.6.1 Checking the connections 71
5.3.6.2 Checking stem is firmly in position 71
5.3.6.3 Checking the headset backlash 71
5.4 Pedelec sale 71
6 Operation
6.1 Risks and hazards 72
6.2 Tips for a greater range 74
6.3 Error message 75
6.3.1 On-board computer 75
6.3.1.1 Less critical errors 75
6.3.1.2 Critical errors 75
6.3.2 Rechargeable battery 75
6.4 Instruction and customer service 76
6.5 Adjusting the pedelec 76
6.5.1 Preparing 76
6.5.2 Pedelec adjustment procedure 77
6.5.3 Determining the sitting position 78
6.5.4 Adjusting the saddle 80
6.5.4.1 Straightening the saddle 80
6.5.4.2 Adjusting the saddle height 80
6.5.4.3 Setting the saddle height with the remote control 81
6.5.4.4 Adjusting the saddle position 82
6.5.4.5 Adjusting the saddle tilt 82
6.5.4.6 Checking saddle stability 82
6.5.5 Handlebars 83
6.5.5.1 Handlebar width 83
6.5.5.2 Hand position 83

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Contents
6.5.5.3 Adjusting the handlebars 83
6.5.6 Stem 84
6.5.6.1 Adjusting the handlebar height with quick release 84
6.5.6.2 Setting the quill stem 85
6.5.6.3 Adjusting the Ahead stem 85
6.5.6.4 Adjusting the angle-adjustable stem 86
6.5.7 Ergonomic handles 87
6.5.7.1 Checking handlebar stability 87
6.5.8 Tyres 88
6.5.9 Brake 89
6.5.9.1 Brake handle position 89
6.5.9.2 Brake handle tilt angle 89
6.5.9.3 Determining the grip distance 90
6.5.9.4 Retracting the brake linings 91
6.5.10 Tyres 92
6.5.10.1 Grip distance on a SHIMANO ST-EF41 brake lever 93
6.5.10.2 Grip distance on a SHIMANO ST-EF41 brake lever 94
6.5.11 Suspension 95
6.5.12 Fork sag 95
6.5.12.1 Adjusting the Suntour fork steel suspension 96
6.5.12.2 Adjusting the Suntour fork air suspension 97
6.5.13 Adjust the rear frame damper sag 98
6.5.13.1 Adjusting the Suntour rear frame damper 99
6.5.14 Fork rebound damping 100
6.5.14.1 Adjusting the Suntour fork rebound damping 101
6.5.15 Adjusting the rear frame damper rebound damper 102
6.5.15.1 Adjusting the Suntour rear frame damper 103
6.5.16 Compression adjuster on rear frame damper 104
6.5.16.1 Adjusting the Suntour compression adjuster 105
6.5.17 Lighting 106
6.5.17.1 Adjusting the lights 106
6.5.18 On-board computer 108
6.5.18.1 Creating a user account 108
6.5.18.2 Connecting the on-board computer with the smartphone 108
6.5.18.3 Update software 108
6.5.18.4 Activating activity tracking 108
6.5.18.5 Setting up the lock function (optional) 108
6.5.18.6 Inserting the display 109
6.5.18.7 Securing the on-board computer (optional) 109
6.5.18.8 Removing the on-board computer 109
6.5.18.9 Adjust on-board computer 110
6.5.18.10 Adjust on-board computer 111
6.5.18.11 Selects the language 111
6.5.18.12 Adjusting the clock 111
6.5.18.13 Adjusting the time format 111
6.5.18.14 Selecting units 111
6.5.18.15 Setting the brightness 111
6.5.18.16 Reset settings 112
6.6 Accessories 113
6.6.1 Child seat 113
6.6.2 Trailer 114
6.6.2.1 Approval for trailer with Enviolo hub 114
6.6.2.2 Approval for trailer with ROHLOFF hub 115
6.6.3 Mobile holder 115
6.6.4 Tubeless and airless tyres 115
6.6.5 Suspension fork coil spring 115
6.6.6 Pannier rack 115
6.6.7 Panniers and cargo boxes 115
6.7 Personal protective equipment and accessories for road safety 116

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Contents
6.8 Before each ride 116
6.9 Straightening the quickly adjustable stem 117
6.10 Using the pannier rack 117
6.11 Raising the kickstand 118
6.12 Using the saddle 118
6.12.1 Using the leather saddle 118
6.13 Using the pedals 118
6.14 Using the multifunctional handlebars or bar ends 118
6.14.1 Using leather handles 118
6.15 Using the bell 118
6.16 Using the battery 119
6.16.1 Removing the battery 119
6.16.1.1 Inserting the battery 119
6.16.2 Charging the battery 120
6.17 Using pedelec with the electric drive system 121
6.17.1 Switching on the electric drive system 121
6.17.2 Switching off the electric drive system 121
6.18 Using the on-board computer 122
6.18.1 Using the diagnosis port 122
6.18.2 Charging the control panel battery 122
6.18.3 Using the riding light 123
6.18.4 Setting the brightness of indicators 123
6.18.5 Using the push assist system 123
6.18.6 Selecting the level of assistance 124
6.19 Brake 125
6.19.1 Using the brake lever 125
6.20 Gear shift 126
6.20.1 Using the derailleur gears 126
6.21 Parking 127
6.21.1 Screwing in the quickly adjustable stem 128
6.21.2 Activating the lock function 129
7 Cleaning, servicing and maintenance
7.1 Before each ride 134
7.1.1 Checking the guards 134
7.1.2 Checking the frame 134
7.1.3 Checking the fork 134
7.1.4 Checking the rear frame damper 134
7.1.5 Checking the pannier rack 134
7.1.6 Checking the guards 134
7.1.7 Checking wheel concentricity 134
7.1.8 Checking the quick releases 134
7.1.9 Checking the suspension seat post 134
7.1.10 Checking the bell 135
7.1.11 Checking the handles 135
7.1.12 Checking the USB cover 135
7.1.13 Checking the lighting 135
7.1.14 Checking the brake 135
7.2 After each ride 136
7.2.1 Cleaning the lights and reflectors 136
7.2.2 Cleaning the suspension fork 136
7.2.3 Caring for the suspension fork 136
7.2.4 Cleaning the pedals 136
7.2.5 Cleaning the brake 136
7.2.6 Cleaning the suspension seat post 136
7.2.7 Cleaning the rear frame damper 136
7.3 Basic cleaning 137
7.3.1 On-board computer and control panel 137
7.3.2 Rechargeable battery 137

MY22B0a - 62_1.0_15.09.2021 6
Contents
7.3.3 Motor 137
7.3.4 Frame, fork, pannier rack, guards and kickstand 138
7.3.5 Stem 138
7.3.6 Handlebars 138
7.3.7 Handles 138
7.3.7.1 Leather handles 138
7.3.8 Seat post 138
7.3.9 Saddle 138
7.3.9.1 Leather saddle 139
7.3.10 Tyres 139
7.3.11 Spokes and spoke nipples 139
7.3.12 Hub 139
7.3.13 Switching elements 139
7.3.13.1 Shifter 139
7.3.14 Cassette, chain wheels and front derailleur 139
7.3.15 Brake 140
7.3.15.1 Brake lever 140
7.3.16 Brake disc 140
7.3.17 Belt 140
7.3.18 Chain 140
7.3.18.1 Chain with all-round chain guard 140
7.4 Servicing 141
7.4.1 Frame 141
7.4.2 Fork 141
7.4.3 Pannier rack 142
7.4.4 Mudguard 142
7.4.5 Servicing the kickstand 142
7.4.6 Stem 142
7.4.7 Handlebars 142
7.4.8 Handle 142
7.4.8.1 Rubber handles 142
7.4.8.2 Leather handle 142
7.4.9 Seat post 143
7.4.9.1 Suspension seat post 143
7.4.9.2 Carbon seat post 143
7.4.10 Rim 143
7.4.11 Leather saddle 143
7.4.12 Hub 143
7.4.13 Spoke nipples 143
7.4.14 Gear shift 144
7.4.14.1 Rear derailleur articulated shafts and jockey wheels 144
7.4.14.2 Shifter 144
7.4.15 Pedal 144
7.4.16 Caring for the chain 144
7.4.16.1 Caring for the chain and all-round chain guard 145
7.4.17 Caring for the battery 145
7.4.18 Caring for the brake 145
7.4.18.1 Caring for the brake 145
7.4.19 Lubricating the Eightpins seat post tube 145
7.5 Maintenance 146
7.5.1 Wheel 146
7.5.1.1 Checking the tyre pressure 146
7.5.1.2 Checking the tyres 148
7.5.1.3 Checking the rims 149
7.5.1.4 Checking the nipple holes 149
7.5.1.5 Checking the nipple well 149
7.5.1.6 Checking the rim hooks 149
7.5.1.7 Checking the spokes 149
7.5.2 Checking the brake system 150

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Contents
7.5.2.1 Checking the hand brake 150
7.5.2.2 Checking the hydraulic system 150
7.5.2.3 Checking the Bowden cables 150
7.5.2.4 Checking the disc brake 151
7.5.2.5 Checking the back-pedal brake 152
7.5.2.6 Checking the rim brake 153
7.5.3 Checking the lighting 154
7.5.4 Checking the stem 155
7.5.5 Check the handlebars 155
7.5.6 Checking the saddle 155
7.5.7 Checking the seat post 155
7.5.8 Checking the chain 155
7.5.9 Checking the chain and belt tension 155
7.5.9.1 Checking the derailleur gears 156
7.5.9.2 Checking the hub gear 156
7.5.10 Checking the gear shift 156
7.5.10.1 Electric gear shift 156
7.5.10.2 Mechanical gear shift 156
7.5.10.3 Checking the derailleur gears 156
7.5.11 Adjusting gear shift 157
7.5.11.1 ROHLOFF hub 157
7.5.12 Bowden-cable-operated gear shift, single-cable 157
7.5.13 Bowden-cable-operated gear shift, dual-cable 157
7.5.14 Bowden-cable-operated twist grip, dual-cable 158
7.5.15 Checking kickstand stability 158
8 Maintenance
8.1 Initial inspection 159
8.2 Maintenance 159
8.3 Component-specific maintenance tasks 159
8.4 Carry out initial inspection 162
8.5 Maintenance instructions 163
8.5.1 Servicing the frame 170
8.5.1.1 Servicing the carbon frame 170
8.5.2 Checking the pannier rack 170
8.5.3 Servicing axle with quick release 170
8.5.4 Maintaining the stem 171
8.5.5 Servicing the gear hub 171
8.5.5.1 Adjusting the hub with cone bearing 171
8.5.6 Servicing the steering headset 172
8.5.7 Servicing the fork 172
8.5.7.1 Servicing the carbon suspension fork 173
8.5.7.2 Servicing the suspension fork 173
8.5.8 Servicing seat post 174
8.5.8.1 Servicing the carbon seat post 174
8.5.8.2 by.schulz suspension seat post 175
8.5.8.3 Suntour suspension seat post 175
8.5.8.4 eightpins NGS2 seat post 176
8.5.8.5 eightpins H01 seat post 182
8.5.9 Rear frame damper 186
8.5.9.1 FOX component-specific maintenance 187
9 Troubleshooting, fault clearance and repair
9.1 Troubleshooting and fault clearance 188
9.1.1 Drive system or on-board computer does not start up 188
9.1.2 Errors in assistance function 189
9.1.3 Battery errors 190
9.1.4 Display screen errors 191
9.1.5 Lighting does not work 191

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Contents
9.1.6 Other errors 192
9.1.7 Suntour suspension fork 193
9.1.7.1 Rebound too fast 193
9.1.7.2 Rebounding too slowly 194
9.1.7.3 Suspension too soft on inclines 195
9.1.7.4 Excessively hard damping on bumps 196
9.1.8 Rear frame damper 197
9.1.8.1 Rebound too fast 197
9.1.8.2 Rebounding too slowly 198
9.1.8.3 Suspension too soft on inclines 199
9.1.8.4 Excessively hard damping on bumps 200
9.2 Repair 201
9.2.1 Original parts and lubricants 201
9.2.2 Replacing the lighting 201
9.2.3 Setting the front light 201
9.2.4 Checking tyre clearance 201
9.2.5 Replacing pedelec components if lock function is installed 202
9.2.5.1 Replacing a smartphone 202
9.2.5.2 Replacing the on-board computer 202
9.2.5.3 Activating the lock function after motor replacement 202
10 Recycling and disposal
10.1 Removal of waste guidelines 203
11 Documents
11.1 Assembly report 205
11.2 Maintenance log 207
11.3 Parts list 211
11.3.1 Cross Lite EVO 1 211
11.3.2 Cross Lite EVO 2 213
11.3.3 Cross Mover EVO 3 215
11.3.4 Cross Rider EVO 2 217
11.3.5 Iconic EVO TR1 27.5" 219
11.3.6 Iconic EVO TR2 27.5" 221
11.4 Charger operating instructions 223
12 Glossary
12.1 Abbreviations 233
12.2 Simplified terms 233
13 Appendix
I. Translation of the original EC/EU Declaration of Conformity 234
II. Declaration of conformity with RED Directive 235
14 Keyword index

MY22B0a - 62_1.0_15.09.2021 9
About these operating instructions
Thank you for your trust!
BULLS pedelecs are premium quality vehicles.
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!
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.
Subject to internal changes
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. In addition to
the functions described here, software changes
may be introduced to rectify errors and extend
functions at any time.
Any significant changes are included in a new
published version of the operating instructions.
All changes to the operating instructions are
published on the following website:
www.bulls.de/service/downloads.
Editing
Text and images:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Translation
RKT Übersetzungs- und Dokumentations-GmbH
Bahnhofstrasse 27
78713 Schramberg, Germany
In case of any questions or problems
regarding these operating instructions,
please contact:
[email protected]