Bosch Kiox User manual

Original operating instructions
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
21-17-2141, 21-17-3139, 21-17-3140
MY21P01 - 22_1.0_17.08.2020
Tecaro Evo NV Belt automatic

MY21P01 - 22_1.0_24.09.2020 2
Contents
Contents
1 About these operating instructions 7
1.1 Manufacturer 7
1.2 Language 7
1.3 Laws, standards and directives 7
1.4 For your information 7
1.4.1 Warnings 7
1.4.2 Markups 8
1.5 Nameplate 9
1.6 Type number and model 10
1.7 Identifying the operating instructions 10
2 Safety 11
2.1 Residual risks 11
2.1.1 Risk of battery fire and explosion 11
2.1.2 Risk of fire and explosion due to
short circuit in the battery 11
2.1.3 Fire hazard caused by overheated
charger 11
2.1.4 Electric shock caused by electric drive
system 11
2.1.5 Risk of a fall due to incorrectly set
quick releases 12
2.1.6 Risk of fire and burns due to hot motor 12
2.1.7 Key breaking off 12
2.2 Toxic substances 12
2.2.1 Brake fluid 12
2.2.2 Suspension oil 12
2.2.3 Defective battery 12
2.3 Requirements for the rider 12
2.4 Vulnerable groups 12
2.5 Personal protective equipment 12
2.6 Safety markings and safety instructions 13
2.7 What to do in an emergency 13
2.7.1 Dangerous situation in road traffic 13
2.7.2 Leaked brake fluid 13
2.7.3 Battery vapours emitted 14
2.7.4 Battery fire 14
2.7.5 Leaked brake fluid 14
2.7.6 Oil and lubricant leaks from the fork 14
2.7.7 Oil and lubricant leaks from the rear
frame damper 14
3Overview 15
3.1 Description 16
3.1.1 Wheel 16
3.1.1.1 Valve 16
3.1.2 Suspension 16
3.1.2.1 Suspension fork 16
3.1.2.2 Steel suspension fork 17
3.1.3 Brake system 17
3.1.3.1 Disc brake 17
3.1.4 Electric drive system 18
3.1.5 Rechargeable battery 18
3.1.5.1 Frame battery 19
3.1.5.2 Pannier rack battery 20
3.1.5.3 Integrated battery 20
3.1.6 On-board computer 21
3.1.6.1 USB port 21
3.1.7 Control panel 21
3.1.8 Riding light 21
3.1.9 Charger 21
3.2 Proper use 22
3.3 Improper use 23
3.3.1 Maximum permitted total weight 24
3.3.2 eBike Connect app 24
3.3.3 Data privacy information 24
3.4 Technical data 25
3.4.1 Pedelec 25
3.4.2 Emissions 25
3.4.3 Tightening torque 25
3.4.4 Bicycle lighting 25
3.4.5 Kiox on-board computer 25
3.4.6 Motor 25
3.4.6.1 Performance Line CX 25
3.4.7 Rechargeable battery 26
3.4.7.1 PowerTube 400 26
3.4.7.2 PowerTube 500 26
3.4.7.3 PowerTube 625 26
3.5 Description of controls and screens 27
3.5.1 Handlebars 27
3.5.2 On-board computer 27
3.5.2.1 Start screen 27
3.5.2.2 Status bar 29
3.5.2.3 Status screen 29
3.5.2.4 Quick menu 29
3.5.2.5 Settings 29
3.5.2.6 Additional journey information for
eShift Shimano DI2 and Rohloff 30
3.5.2.7 Additional eShift system setting 31
3.5.2.8 System message 31
3.5.2.9 ABS indicator lamp 31
3.5.3 Control panel 32
3.5.4 Gears 32
3.5.5 Battery level indicator 32
3.6 Environmental requirements 33
4 Transportation and storing 35
4.1 Physical transport characteristics 35
4.1.1 Designated handles/lifting points 35
4.2 Transportation 36
4.2.1 Using the brake transport securing
system 36
4.2.2 Transporting the pedelec 36
4.2.3 Shipping a pedelec 36
4.2.4 Transporting the battery 36

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Contents
4.2.5 Shipping the battery 36
4.3 Storing 37
4.3.1 Storage mode 37
4.3.1.1 Activating 37
4.3.1.2 Deactivating 37
4.3.2 Break in operation 37
4.3.2.1 Preparing a break in operation 37
4.3.2.2 Carrying out a break in operation 38
5 Assembly 39
5.1 Required tools 39
5.2 Unpacking 39
5.2.1 Scope of delivery 39
5.3 Commissioning 39
5.4 Preparing the battery 40
5.4.1 Checking the battery 40
5.4.2 Retrofitting a PowerTube
Adapter 400 or 500 40
5.4.3 Fit battery cover onto Bosch
PowerTube 625 battery (horizontal) 41
5.4.4 Fit battery cover onto Bosch
PowerTube 500 battery (horizontal) 42
5.5 Preparing the on-board computer 42
5.5.1 Installing the wheel in the Suntour fork 43
5.5.1.1 Screw-on axle (15 mm) 43
5.5.1.2 Screw-on axle (20 mm) 43
5.5.1.3 Quick release axle 44
5.5.1.4 Quick release 45
5.5.2 Checking the stem and handlebars 46
5.5.2.1 Checking the connections 46
5.5.2.2 Firm hold 46
5.5.2.3 Checking the headset backlash 46
5.6 Adjusting gear shift 47
5.6.1 Setting the shift cable play 47
5.6.2 Calibrating 47
5.7 Selling the pedelec 47
6 Operation 48
6.1 Risks and hazards 48
6.1.1 Personal protective equipment 49
6.2 Tips for a greater range 49
6.3 Error message 50
6.3.1 On-board computer 50
6.3.2 Rechargeable battery 52
6.4 Instruction and customer service 53
6.5 Adjusting the pedelec 53
6.5.1 Adjusting the saddle 53
6.5.1.1 Adjusting the saddle tilt 53
6.5.1.2 Determining the seat height 53
6.5.1.3 Adjusting the seat height with quick
release 54
6.5.1.4 Adjusting the seat position 54
6.5.2 Adjusting the handlebars 55
6.5.3 Adjusting the stem 55
6.5.3.1 Adjusting the height of the handlebars 55
6.5.3.2 Adjusting the quick release clamping
force 55
6.5.4 Setting the brake 56
6.5.4.1 Retracting the brake linings 56
6.5.4.2 Setting the grip distance on a
Magura HS22 brake lever 56
6.5.4.3 Setting the grip distance on a
Magura HS33 brake lever 56
6.5.4.4 Setting the pressure point on a
Magura brake lever 57
6.5.5 Adjusting the Suntour fork 58
6.5.5.1 Adjusting the negative deflection 58
6.5.5.2 Adjusting the steel suspension fork
negative deflection 58
6.5.5.3 Adjusting the air suspension fork
negative deflection 59
6.5.5.4 Adjusting the air suspension fork
rebound 59
6.5.6 Setting up the smart app 60
6.5.6.1 Creating a user ID 60
6.5.6.2 Connecting the on-board with the
smartphone 60
6.6 Accessories 61
6.6.1 Child seat 61
6.6.2 Trailer 62
6.6.2.1 Trailer approval for ENVIOLO hub gear 62
6.6.3 Pannier rack 63
6.6.4 Mobile holder 63
6.7 Check list before each ride 64
6.8 Using the kickstand 65
6.8.1 Raising the kickstand 65
6.9 Using the pannier rack 65
6.10 Using the saddle 65
6.11 Rechargeable battery 66
6.11.1 Integrated battery 66
6.11.1.1 Removing the integrated battery 66
6.11.1.2 Inserting the integrated battery 66
6.11.2 Charging the battery 67
6.12 Electric drive system 68
6.12.1 Switching on the electric drive system 68
6.12.2 Switching off the electric drive system 68
6.13 On-board computer 69
6.13.1 Inserting the on-board computer 69
6.13.2 Securing the on-board computer 70
6.13.3 Removing the on-board computer 70
6.13.3.1 Charging on the pedelec 70
6.13.3.2 Charging using the USB port 70
6.13.3.3 Switching the on-board computer on. 71
6.13.4 Switching off the on-board computer 71
6.13.5 Lock (premium function) 71
6.13.6 Using the USB port 71
6.13.6.1 Using the riding light 71

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Contents
6.13.7 Using the push assist system 72
6.13.8 Selecting the level of assistance 72
6.13.9 Operating the on-board computer 73
6.13.10 Opening the start screen 73
6.13.11 Opening screens 73
6.13.12 Opening the quick menu 73
6.13.13 Opening the status screen 73
6.13.14 Changing the settings 73
6.13.14.1Registration with eBike Connect 74
6.13.14.2Resetting daily mileage or average
values manually 74
6.13.14.3Resetting daily mileage or average
values automatically 74
6.13.14.4Resetting the range 74
6.13.14.5Configuring eShift 74
6.13.14.6Switching on Bluetooth® 74
6.13.14.7Switching off Bluetooth® 75
6.13.14.8Adding new device to Bluetooth® 75
6.13.14.9Removing device from Bluetooth® 75
6.13.14.10Setting the brightness 75
6.13.14.11Setting the clock 75
6.13.14.12Setting the date 75
6.13.14.13Setting the time zone 75
6.13.14.14Setting the clock format 75
6.13.14.15Selecting the backlight 75
6.13.14.16Selecting the unit of speed 75
6.13.14.17Select the language 75
6.13.14.18Resetting to factory settings 75
6.14 Brake 76
6.14.1 Using the brake lever 77
6.15 Suspension and damping 78
6.15.1 Adjusting the compression in the
Suntour fork 78
6.16 Gear shift 79
6.16.1 Selecting automatic or manual shift 79
6.16.2 Switching gear in automatic mode 79
6.16.3 Switching gear manually 80
6.16.3.1 Changing down 80
6.16.3.2 Changing up 80
6.17 Parking the pedelec 81
7 Cleaning and servicing 82
7.1 Cleaning after each ride 82
7.1.1 Cleaning the suspension fork 82
7.1.2 Cleaning the pedals 82
7.2 Basic cleaning 83
7.2.1 Cleaning the frame 83
7.2.2 Cleaning the stem 83
7.2.3 Cleaning the wheel 83
7.2.4 Cleaning chain wheels 83
7.2.5 Cleaning the chain 84
7.2.6 Cleaning gear shift 84
7.2.7 Cleaning the battery 84
7.2.8 Cleaning the on-board computer 84
7.2.9 Cleaning the motor 85
7.2.10 Cleaning the brake 85
7.2.11 Cleaning the saddle 85
7.3 Servicing 85
7.3.1 Servicing the frame 85
7.3.2 Servicing the stem 85
7.3.3 Maintaining the suspension fork 86
7.3.4 Servicing the drive elements 86
7.3.5 Servicing the pedals 86
7.3.6 Servicing the chain 86
7.4 Maintenance 86
7.4.1 Wheel 86
7.4.1.1 Checking the tyres 86
7.4.1.2 Checking the rims 86
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 86
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve 87
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 87
7.4.2 Brake system 87
7.4.3 Checking the brake linings for wear 88
7.4.4 Checking the pressure point 88
7.4.5 Checking the brake discs for wear 88
7.4.6 Checking the electrical cables and
brake cables 88
7.4.7 Checking the gear shift 88
7.4.8 Checking the stem 88
7.4.9 Checking the USB port 88
7.4.10 Checking the chain tension 88
8 Maintenance 89
8.1 Suspension system 90
8.1.1 Rear frame damper 90
8.1.2 Suspension fork 91
8.1.3 Suspension seat post 92
8.2 Axle with quick release 92
8.2.1 Checking the quick release 93
8.3 Maintaining the stem 93
8.4 Adjusting the gear shift 93
8.4.1 Cable-operated gear shift, single-cable 93
8.4.2 Cable-operated gear shift, dual-cable 94
8.4.3 Cable-operated twist grip, dual-cable 94
9 Troubleshooting, fault clearance
and repair 95
9.1 Troubleshooting and fault clearance 95
9.1.1 Drive system or on-board computer
does not start up 95
9.1.2 Error message 95
9.1.3 Fault in the assistance system 96
9.1.4 Battery error 97
9.1.5 On-board computer error 98

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Contents
9.1.6 Lighting does not work 98
9.1.7 Other errors 98
9.2 Repair 99
9.2.1 Original parts and lubricants 99
9.2.2 Replacing the lighting 99
9.2.3 Adjusting the headlight 99
9.2.4 Tyre clearance check 99
10 Recycling and disposal 100
11 Documents 101
11.1 Parts list 101
11.1.1 Tecaro EVO NV Belt Automatic 101
11.2 Assembly report 102
11.3 Maintenance instructions 104
11.4 Charger operating instructions 108
12 Glossary 116
12.1 Abbreviations 118
12.2 Simplified terms 118
13 Appendix 119
I. Translation of the original EC/EU
Declaration of Conformity 119
II. Directive declaration of conformity
with RED Directive 120
III. Declaration of conformity for
incomplete machine 121
14 Keyword index 124

MY21P01 - 22_1.0_24.09.2020 6
About these operating instructions
Thank you for your trust!
Pegasus 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 and follow
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!
These 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:
https://www.pegasus-
bikes.com/service/
downloads.html
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
In case of any questions or problems
regarding these operating instructions,
please contact:
[email protected]
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.

MY21P01 - 22_1.0_24.09.2020 7
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.: [phone]
Fax: [phone]
E-mail: [email protected]
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:
https://www.pegasus-bikes.com/service/
downloads.html.
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 – Pannier racks 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
!

MY21P01 - 22_1.0_24.09.2020 8
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
heading indicates
components which can
be used as an
alternative.
Table 1: Markups

MY21P01 - 22_1.0_24.09.2020 9
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
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
No. Designation Description
1CEmarking 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 2020 to July 2021.
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

MY21P01 - 22_1.0_24.09.2020 10
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
21-17-2141 Tecaro Evo NV Belt
Automatic, Wave City and trekking bicycle
21-17-3139 Tecaro Evo NV Belt
Automatic, Gent City and trekking bicycle
21-18-3140 Tecaro Evo NV Belt
Automatic, Trapez City and trekking bicycle
Table 3: Type number, model and pedelec type
Identification number MY21P01 - 22_1.0_24.09.2020

MY21P01 - 22_1.0_24.09.2020 11
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 keep it under observation 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.

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Safety
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.
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.

MY21P01 - 22_1.0_24.09.2020 13
Safety
2.6 Safety markings and safety
instructions
The nameplate contains these safety markings
and safety instructions:
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!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 4: Meaning of safety markings
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

MY21P01 - 22_1.0_24.09.2020 14
Safety
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.
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.

MY21P01 - 22_1.0_24.09.2020 15
Overview
3Overview
Figure 2: Pedelec viewed from right: BULLS Copperhead Evo AM3 used as example
1 Front wheel
2Fork
3 Front wheel guard
4 Headlight
5 Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Reflector and rear light
12 Rear wheel guard
13 Kickstand
14 Rear wheel
15 Chain
16 Chain guard
17 Motor
18 Pedal
19 Battery and nameplate
1
2
4
8910
15 16 19
5
67
17
3
1112
13
14
18

MY21P01 - 22_1.0_24.09.2020 16
Overview
3.1 Description
3.1.1 Wheel
Figure 3: Visible wheel components
1Tyres
2 Rim
3 Spoke
4 Spoke nipples
5Hub
6Valve
The wheel comprises the wheel itself, an inner
tube with a valve and a tyre.
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The pedelec has either
• a classic Dunlop valve,
• a French valve (also known as a Sclaverand or
Presta valve) or
• a Schrader valve.
3.1.2 Suspension
3.1.2.1 Suspension fork
Unlike a rigid fork, a suspension fork has two
functions which improve floor contact and comfort:
suspension and damping. The suspension prevents
an impact, such as one caused by a stone lying in the
pedelec's path, from being channelled directly into
the rider's body via the fork. The impact is absorbed
by the suspension system instead. This causes the
suspension fork to compress.
Figure 4: Pedelec without suspension (1) and with
suspension (2)
After compressing, the suspension fork returns to
its original position. If there is a damper, it
decelerates movement, preventing the
suspension system from springing back in an
uncontrolled manner and stopping the fork from
vibrating up and down. Dampers which dampen
compressive deflection movements, i.e. a
compression load, are called compression
dampers or compression dashpots.
Dampers which dampen rebound deflection
movements, i.e. a rebound load, are called
rebound dampers or dashpots.
The compression can be disabled in any suspension
fork. A suspension fork will then behave like a rigid
fork.
1
2
3
6
5
4
12

MY21P01 - 22_1.0_24.09.2020 17
Overview
3.1.2.2 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 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
1Brakedisc
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 cables 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

MY21P01 - 22_1.0_24.09.2020 18
Overview
3.1.4 Electric drive system
The pedelec is driven by muscle power applied to
the chain drive. The force which is applied by
pedalling in the direction of travel drives the front
chain wheel. The chain transmits the force onto
the rear chain wheel and then onto the rear wheel.
Figure 7: Diagram of mechanical drive system
1 Direction of travel
2 Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
The pedelec also has an integrated electric drive
system in addition to its mechanical drive system.
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the rider’s pedalling
motion. The pre-set level of assistance
determines the motor output.
The pedelec does not have a separate emergency
shut-off button. The electric drive system can be
stopped by removing the on-board computer in the
event of an emergency. 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.
The motor switches off automatically as soon as
the rider no longer pedals, the temperature is
outside the permitted range, there is an overload
or the shut-off speed of 25 km/h has been
reached.
The electric drive system is made up of
8 components:
Figure 8: Diagram of electric drive system
1 Headlight
2 On-board computer,
3 Control panel
4.1 Integrated battery
4.2 Frame battery
4.3 Pannier rack battery
5 Rear light
6 Electric gear shift (alternative)
7Motor
• A charger designed for the battery.
A push assist system can be activated. The speed
depends on the selected gear. The motor
continues to drive the pedelec as long as the rider
presses the push assist button on the handlebars.
The speed can be a maximum of 6 km/h in this
case. The electric drive system stops when the
push assist button is released.
3.1.5 Rechargeable battery
Bosch batteries are lithium ion batteries which are
developed and manufactured to the latest
technical standards. These batteries meet and
exceed applicable industrial safety standards.
The battery has an internal electronic protection
circuit, which is specifically designed for the
charger and the pedelec. The battery temperature
is monitored at all times. Each individual cell in a
Bosch battery is protected by a steel cup and
cased in a plastic housing. You must not open this
housing. You must also avoid mechanical loads or
exposure to intense heat since they may damage
the battery cells and cause flammable contents to
leak out.
1
2
543
B
1
34.14.3 4.2
5
67
2

MY21P01 - 22_1.0_24.09.2020 19
Overview
The battery is protected against deep discharge,
overcharging, overheating and short circuit. In the
event of a hazard, a protective circuit switches the
battery off automatically.
The battery has a high energy content when
charged. The substances in lithium-ion battery
cells may become inflammable under certain
conditions. 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 (e.g. the pedelec is stationary) and no
button has been pressed on the on-board
computer or the control panel, the electric drive
system and the battery switch off automatically 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 Bosch
battery will age naturally, even if it is not being
used.
Its battery life can be extended if the battery is well
maintained and, more importantly, stored at the
correct temperatures. 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 should 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.
Three different types of frame batteries can be
fitted: A frame battery, a pannier rack battery or an
integrated battery
3.1.5.1 Frame battery
Figure 9: Details of frame battery
1 Battery housing
2 Battery lock
3 Key for the battery lock
4 On-Off button (battery)
5 Battery level indicator
6 Charging port cover
7 Port for charger plug
PowerPack 300 PowerPack 400 PowerPack 500
Table 6: Overview of frame batteries
1
2
4
5
67
3

MY21P01 - 22_1.0_24.09.2020 20
Overview
3.1.5.2 Pannier rack battery
Three different types of pannier rack batteries can
be fitted:
Figure 10: Details of pannier rack battery
1 Battery housing
2 Charging port for charger plug
3 Charging port cover
5Batterylock
6 Key for the battery lock
7Battery level indicator
8 On-Off button (battery)
3.1.5.3 Integrated battery
Two different types of pannier rack batteries can
be fitted:
Figure 11: Example of integrated battery in detail
1 Key for the battery lock
2 Retainer guard
3 Securing hook
4 On-Off button (battery)
5Battery level indicator
6 Integrated battery housing
PowerPack 300 PowerPack 400 PowerPack 500
Table 7: Overview of pannier rack batteries
1
2
3
4
5
6
78
PowerTube 400
(vertical/horizontal) PowerTube 500 (vertical/horizontal) PowerTube 625 (vertical/ horizontal)
Table 8: Overview of frame batteries
1
2
3
4
5
2
6