Bosch KB160 KD Series Wiring diagram

IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Translation of original operating instructions for
KETTLER pedelecs with BOSCH KIOX
on-board computer
E-TRANSHILL CX12
KB160-xxKD, KB160-xxKW
MY22K0a - 52_1.0_20:04:2021

MY22K0a - 52_1.0_30.11.2021 1
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
3.3.4 Wheel 32
3.3.4.1 Tyres 32
3.3.4.2 Rim 32
3.3.4.3 Valve 32
3.3.4.4 Spoke 33
3.3.4.5 Spoke nipples 33
3.3.4.6 Hub 33
3.3.5 Braking system 34
3.3.5.1 Mechanical brake 34
3.3.5.2 Hydraulic brake 34
3.3.5.3 Disc brake 35
3.3.6 Seat post 36
3.3.6.1 Patent seat post 36
3.3.6.2 Suspension seat post 36
3.3.7 Mechanical drive system 37
3.3.7.1 Chain drive layout 37
3.3.7.2 Belt drive layout 37
3.3.8 Electric drive system 38
3.3.8.1 Motor 38
3.3.8.2 Rechargeable battery 38
3.3.8.3 Charger 39
3.3.8.4 Lighting 39
3.3.8.5 Integrated battery 39
3.3.9 On-board computer 40
3.3.9.1 Display 40
3.4 Description of controls and screens 41
3.4.1 Handlebars 41
3.4.2 Control panel 42
3.4.2.1 System message 43
3.4.2.2 Creating a user account 44
3.4.2.3 Software updates 44
3.4.2.4 Activity tracking 44
3.4.2.5 Lock function 44
3.4.3 Battery level indicator (battery) 45
3.4.4 Gear shift 46
3.4.4.1 SHIMANO SW-E7000 derailleur gears 46
3.4.5 Hand brake 47
3.4.6 Fork lock 48
3.4.6.1 SR Suntour 48
3.5 Technical data 49
3.5.1 Pedelec 49
3.5.2 Emissions 49
3.5.3 Bicycle lighting 49
3.5.4 Display mount 49
3.5.5 LED Remote on-board computer 49
3.5.6 BOSCH Kiox300 display 49
3.5.7 BOSCH Performance Line CX motor 49
3.5.8 BOSCH PowerTube 750 battery 50
3.5.9 Tightening torques 51
4 Transporting and storing
4.1 Weight and dimensions for transportation 53

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Contents
4.2 Designated handles, lifting points 53
4.3 Transportation 54
4.3.1 Using the transport securing system 54
4.3.2 Transporting the pedelec 54
4.3.3 Shipping a pedelec 54
4.3.4 Transporting the battery 54
4.3.5 Shipping the battery 54
4.4 Storing 55
4.4.1 Break in operation 55
4.4.1.1 Preparing a break in operation 55
4.4.1.2 Carrying out a break in operation 55
5 Assembly
5.1 Unpacking 56
5.2 Required tools 56
5.3 Commissioning 57
5.3.1 Checking the battery 57
5.3.1.1 Securing the PowerTube BS3 battery mount 58
5.3.2 Preparing the wheel 59
5.3.3 Installing the wheel in the SUNTOUR fork 60
5.3.3.1 Screw-on axle (12AH2 and 15AH2) 60
5.3.3.2 20 mm cross axle 61
5.3.3.3 Q-LOC quick release 63
5.3.4 Fitting the pedals 64
5.3.5 Preparing the LIMOTEC seat post 65
5.3.6 Checking the stem and handlebars 66
5.3.6.1 Checking the connections 66
5.3.6.2 Checking stem is firmly in position 66
5.3.6.3 Checking the headset backlash 66
5.4 Pedelec sale 66
6 Operation
6.1 Risks and hazards 67
6.2 Tips for a greater range 69
6.3 Error message 70
6.3.1 On-board computer 70
6.3.1.1 Less critical errors 70
6.3.1.2 Critical errors 70
6.3.2 Rechargeable battery 70
6.4 Instruction and customer service 71
6.5 Adjusting the pedelec 71
6.5.1 Preparing 71
6.5.2 Pedelec adjustment procedure 72
6.5.3 Determining the sitting position 73
6.5.4 Adjusting the saddle 75
6.5.4.1 Straightening the saddle 75
6.5.4.2 Adjusting the saddle height 75
6.5.4.3 Setting the saddle height with the remote control 76
6.5.4.4 Adjusting the saddle position 77
6.5.4.5 Adjusting the saddle tilt 77
6.5.4.6 Checking saddle stability 77
6.5.5 Handlebars 78
6.5.5.1 Handlebar width 78
6.5.5.2 Hand position 78
6.5.5.3 Adjusting the handlebars 78
6.5.6 Stem 79
6.5.6.1 Adjusting the handlebar height with quick release 79
6.5.6.2 Setting the quill stem 80
6.5.6.3 Adjusting the Ahead stem 80

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Contents
6.5.6.4 Adjusting the angle-adjustable stem 81
6.5.7 Ergonomic handles 82
6.5.7.1 Checking handlebar stability 82
6.5.8 Tyres 83
6.5.9 Brake 84
6.5.9.1 Brake handle position 84
6.5.9.2 Brake handle tilt angle 84
6.5.9.3 Determining the grip distance 85
6.5.9.4 Retracting the brake linings 86
6.5.10 Tyres 87
6.5.10.1 Grip distance on a SHIMANO ST-EF41 brake lever 88
6.5.10.2 Grip distance on a SHIMANO ST-EF41 brake lever 89
6.5.11 Suspension 90
6.5.12 Fork sag 90
6.5.12.1 Adjusting the Suntour fork steel suspension 91
6.5.12.2 Adjusting the Suntour fork air suspension 92
6.5.13 Adjust the rear frame damper sag 93
6.5.14 Fork rebound damping 94
6.5.14.1 Adjusting the Suntour fork rebound damping 95
6.5.15 Lighting 96
6.5.15.1 Adjusting the lights 96
6.5.16 On-board computer 98
6.5.16.1 Creating a user account 98
6.5.16.2 Connecting the on-board computer with the smartphone 98
6.5.16.3 Update software 98
6.5.16.4 Activating activity tracking 98
6.5.16.5 Setting up the lock function (optional) 99
6.6 Accessories 100
6.6.1 Child seat 100
6.6.2 Trailer 101
6.6.2.1 Approval for trailer with Enviolo hub 101
6.6.2.2 Approval for trailer with ROHLOFF hub 102
6.6.3 Mobile holder 102
6.6.4 Tubeless and airless tyres 102
6.6.5 Suspension fork coil spring 102
6.6.6 Pannier rack 102
6.6.7 Panniers and cargo boxes 102
6.7 Personal protective equipment and accessories for road safety 103
6.8 Before each ride 103
6.9 Straightening the quickly adjustable stem 104
6.10 Using the pannier rack 104
6.11 Raising the kickstand 105
6.12 Using the saddle 105
6.12.1 Using the leather saddle 105
6.13 Using the pedals 105
6.14 Using the multifunctional handlebars or bar ends 105
6.14.1 Using leather handles 105
6.15 Using the bell 105
6.16 Using the battery 106
6.16.1 Removing the battery 106
6.16.1.1 Inserting the battery 106
6.16.2 Charging the battery 107
6.17 Using pedelec with the electric drive system 108
6.17.1 Switching on the electric drive system 108
6.17.2 Switching off the electric drive system 108
6.18 Using the on-board computer 109
6.18.1 Using the diagnosis port 109
6.18.2 Charging the control panel battery 109
6.18.3 Using the riding light 110

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Contents
6.18.4 Setting the brightness of indicators 110
6.18.5 Using the push assist system 110
6.18.6 Selecting the level of assistance 111
6.19 Brake 112
6.19.1 Using the brake lever 112
6.20 Gear shift 113
6.20.1 Using the derailleur gears 113
6.21 Suspension and damping 114
6.21.1 Adjusting the Suntour compression adjuster 115
6.22 Parking the pedelec 116
6.22.1 Screwing in the quickly adjustable stem 117
6.22.2 Activating the lock function 118
7 Cleaning, servicing and maintenance
7.1 Before each ride 123
7.1.1 Checking the guards 123
7.1.2 Checking the frame 123
7.1.3 Checking the fork 123
7.1.4 Checking the rear frame damper 123
7.1.5 Checking the pannier rack 123
7.1.6 Checking the guards 123
7.1.7 Checking wheel concentricity 123
7.1.8 Checking the quick releases 123
7.1.9 Checking the suspension seat post 123
7.1.10 Checking the bell 124
7.1.11 Checking the handles 124
7.1.12 Checking the USB cover 124
7.1.13 Checking the lighting 124
7.1.14 Checking the brake 124
7.2 After each ride 125
7.2.1 Cleaning the lights and reflectors 125
7.2.2 Cleaning the suspension fork 125
7.2.3 Caring for the suspension fork 125
7.2.4 Cleaning the pedals 125
7.2.5 Cleaning the brake 125
7.2.6 Cleaning the suspension seat post 125
7.2.7 Cleaning the rear frame damper 125
7.3 Basic cleaning 126
7.3.1 On-board computer and control panel 126
7.3.2 Rechargeable battery 126
7.3.3 Motor 126
7.3.4 Frame, fork, pannier rack, guards and kickstand 127
7.3.5 Stem 127
7.3.6 Handlebars 127
7.3.7 Handles 127
7.3.7.1 Leather handles 127
7.3.8 Seat post 127
7.3.9 Saddle 127
7.3.9.1 Leather saddle 128
7.3.10 Tyres 128
7.3.11 Spokes and spoke nipples 128
7.3.12 Hub 128
7.3.13 Switching elements 128
7.3.13.1 Shifter 128
7.3.14 Cassette, chain wheels and front derailleur 128
7.3.15 Brake 129
7.3.15.1 Brake lever 129
7.3.16 Brake disc 129
7.3.17 Belt 129

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Contents
7.3.18 Chain 129
7.3.18.1 Chain with all-round chain guard 129
7.4 Servicing 130
7.4.1 Frame 130
7.4.2 Fork 130
7.4.3 Pannier rack 131
7.4.4 Mudguard 131
7.4.5 Servicing the kickstand 131
7.4.6 Stem 131
7.4.7 Handlebars 131
7.4.8 Handle 131
7.4.8.1 Rubber handles 131
7.4.8.2 Leather handle 131
7.4.9 Seat post 132
7.4.9.1 Suspension seat post 132
7.4.9.2 Carbon seat post 132
7.4.10 Rim 132
7.4.11 Leather saddle 132
7.4.12 Hub 132
7.4.13 Spoke nipples 132
7.4.14 Gear shift 133
7.4.14.1 Rear derailleur articulated shafts and jockey wheels 133
7.4.14.2 Shifter 133
7.4.15 Pedal 133
7.4.16 Caring for the chain 133
7.4.16.1 Caring for the chain and all-round chain guard 134
7.4.17 Caring for the battery 134
7.4.18 Caring for the brake 134
7.4.18.1 Caring for the brake 134
7.4.19 Lubricating the Eightpins seat post tube 134
7.5 Maintenance 135
7.5.1 Wheel 135
7.5.1.1 Checking the tyre pressure 135
7.5.1.2 Checking the tyres 137
7.5.1.3 Checking the rims 138
7.5.1.4 Checking the nipple holes 138
7.5.1.5 Checking the nipple well 138
7.5.1.6 Checking the rim hooks 138
7.5.1.7 Checking the spokes 138
7.5.2 Checking the brake system 139
7.5.2.1 Checking the hand brake 139
7.5.2.2 Checking the hydraulic system 139
7.5.2.3 Checking the Bowden cables 139
7.5.2.4 Checking the disc brake 140
7.5.2.5 Checking the back-pedal brake 141
7.5.2.6 Checking the rim brake 142
7.5.3 Checking the lighting 143
7.5.4 Checking the stem 144
7.5.5 Check the handlebars 144
7.5.6 Checking the saddle 144
7.5.7 Checking the seat post 144
7.5.8 Checking the chain 144
7.5.9 Checking the chain and belt tension 144
7.5.9.1 Checking the derailleur gears 145
7.5.9.2 Checking the hub gear 145
7.5.10 Checking the gear shift 145
7.5.10.1 Electric gear shift 145
7.5.10.2 Mechanical gear shift 145
7.5.10.3 Checking the derailleur gears 145

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Contents
7.5.11 Adjusting gear shift 146
7.5.11.1 ROHLOFF hub 146
7.5.12 Bowden-cable-operated gear shift, single-cable 146
7.5.13 Bowden-cable-operated gear shift, dual-cable 146
7.5.14 Bowden-cable-operated twist grip, dual-cable 147
7.5.15 Checking kickstand stability 147
8 Maintenance
8.1 Initial inspection 148
8.2 Maintenance 148
8.3 Component-specific maintenance tasks 148
8.4 Carry out initial inspection 151
8.5 Maintenance instructions 152
8.5.1 Servicing the frame 159
8.5.1.1 Servicing the carbon frame 159
8.5.2 Checking the pannier rack 159
8.5.3 Servicing axle with quick release 159
8.5.4 Maintaining the stem 160
8.5.5 Servicing the gear hub 160
8.5.5.1 Adjusting the hub with cone bearing 160
8.5.6 Servicing the steering headset 161
8.5.7 Servicing the fork 161
8.5.7.1 Servicing the carbon suspension fork 162
8.5.7.2 Servicing the suspension fork 162
8.5.8 Servicing seat post 163
8.5.8.1 Servicing the carbon seat post 163
8.5.8.2 by.schulz suspension seat post 164
8.5.8.3 Suntour suspension seat post 164
8.5.8.4 eightpins NGS2 seat post 165
8.5.8.5 eightpins H01 seat post 171
8.5.9 Rear frame damper 175
8.5.9.1 FOX component-specific maintenance 176
9 Troubleshooting, fault clearance and repair
9.1 Troubleshooting and fault clearance 177
9.1.1 Drive system or on-board computer does not start up 177
9.1.2 Errors in assistance function 178
9.1.3 Battery errors 179
9.1.4 Errors on the control panel 180
9.1.5 Lighting does not work 180
9.1.6 Other errors 181
9.1.7 Suntour suspension fork 182
9.1.7.1 Rebound too fast 182
9.1.7.2 Rebounding too slowly 183
9.1.7.3 Suspension too soft on inclines 184
9.1.7.4 Excessively hard damping on bumps 185
9.1.8 RockShox suspension fork 186
9.1.8.1 Rebound too fast 186
9.1.8.2 Rebounding too slowly 187
9.1.8.3 Suspension too soft on inclines 188
9.1.8.4 Excessively hard damping on bumps 189
9.1.9 Rear frame damper 190
9.1.9.1 Rebound too fast 190
9.1.9.2 Rebounding too slowly 191
9.1.9.3 Suspension too soft on inclines 192
9.1.9.4 Excessively hard damping on bumps 193
9.1.10 RockShox rear frame damper 194
9.1.10.1 Rebound too fast 194
9.1.10.2 Rebounding too slowly 195

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Contents
9.1.10.3 Suspension too soft on inclines 196
9.1.10.4 Excessively hard damping on bumps 197
9.2 Repair 198
9.2.1 Original parts and lubricants 198
9.2.2 Replacing the lighting 198
9.2.3 Setting the front light 198
9.2.4 Checking tyre clearance 198
9.2.5 Replacing pedelec components if lock function is installed 199
9.2.5.1 Replacing a smartphone 199
9.2.5.2 Replacing the on-board computer 199
9.2.5.3 Activating the lock function after motor replacement 199
10 Recycling and disposal
10.1 Removal of waste guidelines 200
11 Documents
11.1 Assembly report 202
11.2 Maintenance log 204
11.3 Parts list 208
11.3.1 E-TRANSHILL CX12 208
11.4 Charger operating instructions 210
12 Glossary
12.1 Abbreviations 220
12.2 Simplified terms 220
13 Appendix
I. Translation of the original EC/EU Declaration of Conformity 221
II. Declaration of conformity with RED Directive 222
14 Keyword index

MY22K0a - 52_1.0_30.11.2021 9
About these operating instructions
Thank you for your trust!
KETTLER 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:
https://www.kettler-alu-
rad.de/gb/en/index/
service.html.
Copyright
© KETTLER Alu-Rad GmbH
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:
https://www.kettler-alu-rad.de/gb/en/index/
service.html
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]