Bosch Premio EVO Wiring diagram

MY2 3 P 0 a - 4 2 _ 1.0 _ 1 9.10 . 2 0 22
23-15-2069 … 23-15-2071, 23-15-2087 … 23-15-2090, 23-15-2092, 23-15-21##,
23-15-2106 … 23-15-2109, 23-15-2111, 23-15-2112, 23-15-2114 … 23-15-2118, 23-15-2120,
23-15-2121, 23-15-2123 … 23-15-2130, 23-15-2132, 23-15-2133, 23-15-2135, 23-15-2136,
23-15-2138, 23-15-2139, 23-15-2141, 23-15-2145 … 23-15-2150, 23-15-2152, 23-15-2153,
23-15-2167, 23-15-2169, 23-15-2170, 23-15-2172, 23-15-2239, 23-15-2240, 23-15-30##,
23-15-3050, 23-15-3052
Translation of original operating instructions for
PEGASUS pedelecs with BOSCH KIOX 300 Display and
LED Remote on-board computer
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Premio EVO
11 Lite, 5F Lite Belt, NV Lite Belt, ABS
Savino EVO
5F Lite, 12 Lite, 5F Lite Belt
Strong EVO
11 Lite, 5F Lite Belt
Ravenna EVO
NV Belt NL, 5F Belt NL

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Contents
Contents
1 About these operating instructions
1.1 Manufacturer 13
1.2 Laws, standards and directives 13
1.3 Language 13
1.4 For your information 13
1.4.1 Warnings 13
1.4.2 Markups 13
1.5 Aim of the operating instructions 14
1.6 Type number and model 15
1.7 Frame number 15
1.8 Identifying the operating instructions 15
2 Safety
2.1 Residual risk 16
2.1.1 Risk of fire and explosion 16
2.1.2 Electric shock 18
2.1.3 Risk of a crash 18
2.1.4 Risk of amputation 18
2.1.5 Key breaking off 18
2.1.6 Malfunctions due to Bluetooth® 19
2.2 Toxic substances 20
2.2.1 Carcinogenic substances 20
2.2.2 Toxic substances 20
2.2.3 Irritants and corrosive substances 20
2.3 Requirements for the pedelec rider 21
2.4 Vulnerable groups 21
2.5 Personal protective equipment 21
2.6 Safety guards 21
2.7 Safety markings and safety instructions 22
2.8 What to do in an emergency 22
2.8.1 Dangerous situation in road traffic 22
2.8.2 Leaked brake fluid 22
2.8.3 Battery vapour emission 23
2.8.4 Battery fire 23
2.8.5 Oil and lubricant leaks from the rear frame damper 23
2.8.6 Oil and lubricant leaks from the fork 23
2.9 Data privacy information 24
3 Description
3.1 Proper use 25
3.1.1 Pedelec type 25
3.1.2 Improper use 25
3.1.3 Maximum permitted total weight (PTW) 26
3.1.4 Environmental requirements 27
3.1.5 Area of use 27
3.2 Nameplate 29
3.3 Components 30
3.3.1 Overview 30
3.3.2 Chassis 31
3.3.2.1 Frame 31
3.3.2.2 Steering system 33
3.3.2.3 Steering headset 33
3.3.2.4 Stem 33
3.3.2.5 Handlebars 34
3.3.2.6 Suspension fork 34

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Contents
3.3.2.7 SR SUNTOUR 2CR-PCS 41
3.3.2.8 SR SUNTOUR RLR 42
3.3.2.9 SR SUNTOUR LOR 43
3.3.2.10 SR SUNTOUR LO 44
3.3.2.11 SR SUNTOUR RL 45
3.3.2.12 SR SUNTOUR HLO 46
3.3.3 Wheel 47
3.3.3.1 Tyres 47
3.3.3.2 Tube-type tyre 47
3.3.3.3 Rim 50
3.3.3.4 Valve 50
3.3.3.5 Spoke 50
3.3.3.6 Spoke nipples 50
3.3.3.7 Hub 51
3.3.4 Saddle 52
3.3.4.1 Ladies’ saddle 53
3.3.4.2 Men’s saddle 53
3.3.5 Seat post 54
3.3.5.1 Patent seat post 54
3.3.5.2 Suspension seat post 54
3.3.6 Brake 56
3.3.6.1 Mechanical brake 56
3.3.6.2 Hydraulic brake 56
3.3.6.3 Disc brake 57
3.3.6.4 Back-pedal brake 58
3.3.6.5 BOSCH ABS 59
3.3.7 Mechanical drive system 61
3.3.7.1 Chain drive layout 61
3.3.7.2 Belt drive layout 61
3.3.8 Electric drive system 62
3.3.8.1 Motor 62
3.3.8.2 Charger 62
3.3.8.3 Lighting 62
3.3.8.4 Rechargeable battery 63
3.3.9 On-board computer 64
3.3.9.1 Display 64
3.4 Description of controls and screens 65
3.4.1 Handlebars 65
3.4.2 BOSCH LED Remote on-board computer 66
3.4.2.1 System message 67
3.4.2.2 Creating a user account 68
3.4.2.3 Software updates 68
3.4.2.4 Activity tracking 68
3.4.2.5 Lock function 68
3.4.3 BOSCH ABS indicator lamp 69
3.4.4 Display 70
3.4.4.1 Start screen 70
3.4.4.2 Status screen 71
3.4.4.3 TRIP screen 72
3.4.4.4 Range screen 72
3.4.4.5 Fitness screen 73
3.4.4.6 ABS screen 73
3.4.4.7 Settings 74
3.4.5 Handbrake 75
3.4.6 Suspension and damping 76
3.4.6.1 Air valve and sag setting wheel 76
3.4.7 Gear shift 77
3.4.7.1 SHIMANO derailleur gears 77

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Contents
3.4.8 Gear shift 78
3.4.8.1 SHIMANO SL-T6000 derailleur gears 78
3.4.8.2 SHIMANO SW-E7000 derailleur gears 79
3.4.8.3 SHIMANO hub gear 80
3.4.8.4 ENVIOLO hub gear 81
3.4.9 Battery level indicator (battery) 82
3.4.9.1 Battery level indicator (battery) 82
3.5 Technical data 83
3.5.1 Pedelec 83
3.5.2 Emissions 83
3.5.3 Bicycle lighting 83
3.5.4 Display mount 83
3.5.5 LED Remote on-board computer 83
3.5.6 BOSCH Kiox 300 display 83
3.5.7 BOSCH Performance Line CX motor 83
3.5.8 Rechargeable battery 84
3.5.8.1 BOSCH PowerTube 500 battery 84
3.5.8.2 BOSCH PowerTube 625 battery 84
3.5.8.3 BOSCH PowerTube 750 battery 84
3.5.9 Tyres 85
3.5.9.1 SCHWALBE puncture protection level 85
3.5.9.2 Tyres, SUPERO puncture protection level 86
3.5.9.3 MAXXIS®, puncture protection level 87
3.5.10 Fork 88
3.5.10.1 Maximum rider weight for SR SUNTOUR steel suspension fork 88
3.5.11 Saddle 89
3.5.11.1 BROOKS ENGLAND saddle width 89
3.5.11.2 ERGON 89
3.5.11.3 SELLE ROYAL saddle width 89
3.5.12 Seat post 90
3.5.12.1 LIMOTEC A3/A3 Plus suspension seat post 90
3.5.13 Torque 92
4 Transporting and storing
4.1 Weight and dimensions for transportation 104
4.2 Designated handles, lifting points 104
4.3 Transportation 105
4.3.1 Using the transport securing system 105
4.3.2 Transporting the pedelec 105
4.3.2.1 By car 105
4.3.2.2 By train 105
4.3.2.3 By local transport 106
4.3.2.4 By long-distance bus 106
4.3.2.5 On flights 106
4.3.3 Shipping a pedelec 106
4.3.4 Transporting the battery 106
4.3.5 Shipping the battery 106
4.4 Storing 107
4.4.1 Pedelec 107
4.4.2 On-board computer, display and charger 107
4.4.3 Rechargeable battery 107
4.4.4 Break in operation 108
4.4.4.1 Preparing a break in operation 108
4.4.4.2 Carrying out a break in operation 108
5 Assembly
5.1 Unpacking 109
5.2 Required tools 109

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Contents
5.3 Commissioning 110
5.3.1 Checking the battery 110
5.3.2 Adjusting the suspension system to body weight 111
5.3.2.1 Adjusting SR Suntour suspension elements 111
5.3.3 Adjusting the LIMOTEC seat post 112
5.3.4 Installing the wheel in the SUNTOUR fork 113
5.3.4.1 Screw-on axle (12AH2 and 15AH2) 113
5.3.4.2 20 mm cross axle 114
5.3.4.3 Q-LOC quick release 116
5.3.5 Preparing the wheel 117
5.3.6 Fitting the pedals 118
5.3.7 Checking the stem and handlebars 119
5.3.7.1 Checking the connections 119
5.3.7.2 Checking stem is firmly in position 119
5.3.7.3 Checking the bearing clearance 119
5.4 Selling the pedelec 119
6 Operation
6.1 Risks and hazards 120
6.2 Tips for a greater range 122
6.3 Error message 123
6.3.1 On-board computer 123
6.3.1.1 Less critical errors 123
6.3.1.2 Critical errors 123
6.3.2 Rechargeable battery 123
6.4 Instruction and customer service 124
6.5 Adjusting the pedelec 124
6.5.1 Preparing 124
6.5.2 Determining the sitting position 125
6.5.3 Seat post 126
6.5.3.1 Adjusting the seat post to body weight 126
6.5.4 Saddle 126
6.5.4.1 Replacing the saddle 126
6.5.4.2 Determining saddle shape 127
6.5.4.3 Determining minimum saddle width with corrugated cardboard 128
6.5.4.4 Determining minimum saddle width with gel cushion 128
6.5.4.5 Calculating the saddle width 129
6.5.4.6 Selecting the saddle hardness 129
6.5.4.7 Adjusting the saddle hardness 129
6.5.4.8 Straighten saddle 130
6.5.4.9 Adjusting the saddle height 130
6.5.4.10 Setting the saddle height with the remote control 131
6.5.4.11 Adjusting the saddle position 132
6.5.4.12 Adjusting the saddle tilt 132
6.5.4.13 Checking saddle stability 132
6.5.5 Handlebars 133
6.5.5.1 Replace handlebars 133
6.5.5.2 Adjusting the handlebar width 133
6.5.5.3 Adjusting the hand position 133
6.5.5.4 Adjusting the handlebars 134
6.5.6 Stem 135
6.5.6.1 Replacing the handlebars 135
6.5.6.2 Adjusting the handlebar height with quick release 135
6.5.6.3 Checking the stem stability 135
6.5.6.4 Adjusting the quick release clamping force 135
6.5.6.5 Setting the quill stem 136
6.5.6.6 Adjusting the Ahead stem 136
6.5.6.7 Adjusting the angle-adjustable stem 137
6.5.7 Handles 138

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Contents
6.5.7.1 Replacing the handles 138
6.5.7.2 Adjusting ergonomic handles 138
6.5.7.3 Checking handlebar stability 138
6.5.8 Tyres 139
6.5.8.1 Replacing tyres 139
6.5.8.2 Adjust tyre pressure 139
6.5.9 Brake 141
6.5.9.1 Replacing brakes 141
6.5.9.2 Retracting the brake linings 141
6.5.9.3 Change handbrake position 141
6.5.9.4 Change handbrake inclination angle 142
6.5.9.5 Determining the grip distance 142
6.5.9.6 Grip distance on a SHIMANO ST-EF41 handbrake 143
6.5.9.7 Setting the grip distance for a MAGURA handbrake disc brake 144
6.5.9.8 MAGURA handbrake pressure point 145
6.5.9.9 Grip distance on SHIMANO ST-EF41 handbrake 146
6.5.10 Gear shift 147
6.5.10.1 Replacing the gear shift 147
6.5.10.2 Adjusting the SHIMANO shifter 147
6.5.11 Suspension and damping 148
6.5.12 Adjusting sag (fork) 148
6.5.12.1 Adjusting the sag for the SR SUNTOUR air suspension fork 150
6.5.12.2 Adjusting the sag for the SR SUNTOUR steel suspension fork 154
6.5.13 Fork rebound damping 155
6.5.13.1 Adjusting the SR SUNTOUR fork rebound damping 156
6.5.14 Riding light 157
6.5.14.1 Replacing the headlight 157
6.5.14.2 Replacing the rear light and (spoke) reflector 157
6.5.14.3 Setting the riding light 157
6.5.14.4 Adjusting the headlight 158
6.5.15 On-board computer 159
6.5.15.1 Creating a user account 159
6.5.15.2 Connecting the on-board computer to a smartphone 159
6.5.15.3 Update software 159
6.5.15.4 Activating activity tracking 159
6.5.15.5 Setting up the lock function (optional) 159
6.5.15.6 Inserting the display 160
6.5.15.7 Securing the on-board computer (optional) 160
6.5.15.8 Removing the on-board computer 160
6.5.15.9 Adjust on-board computer 161
6.5.15.10 Adjust on-board computer 162
6.5.15.11 Selects the language 162
6.5.15.12 Adjusts the clock 162
6.5.15.13 Adjusting the time format 162
6.5.15.14 Selecting units 162
6.5.15.15 Setting the brightness 162
6.5.15.16 Reset settings 163
6.6 Accessories 164
6.6.1 Child seat 164
6.6.2 Trailer 165
6.6.2.1 Approval for trailer with Enviolo hub 165
6.6.2.2 Approval for trailer with ROHLOFF hub 166
6.6.3 Pannier rack 166
6.6.4 Panniers and cargo boxes 166
6.6.5 Front baskets 167
6.6.6 Bar ends 167
6.6.7 Kickstands 167
6.6.8 Additional battery headlight 167
6.6.9 Mobile holder 167

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Contents
6.6.10 Suspension fork coil spring 167
6.6.11 Fixed weather protection systems 167
6.7 Personal protective equipment and accessories for road safety 168
6.8 Before each ride 168
6.8.1 Checking the ABS lamp 169
6.9 Straightening the quickly adjustable stem 170
6.10 Using the pannier rack 170
6.11 Raising the kickstand 171
6.12 Using the saddle 171
6.12.1 Using the leather saddle 171
6.13 Using the pedals 171
6.14 Using the bell 171
6.15 Using the handlebars 172
6.15.1 Using multi-position handlebars 172
6.15.2 Using bar ends 172
6.15.3 Using leather handles 172
6.16 Use suspension and damping 173
6.16.1 Locking the suspension 173
6.16.1.1 Locking the SR SUNTOUR suspension fork 173
6.16.2 Adjusting the suspension fork compression damper 174
6.16.2.1 Using SR Suntour high-speed compression damping 175
6.16.2.2 Using the SR Suntour low-speed compression damping 176
6.17 Using the battery 177
6.17.1 Removing the battery 177
6.17.1.1 Inserting the battery 177
6.17.2 Charging the battery 178
6.18 Using the electric drive system 179
6.18.1 Switching on the electric drive system 179
6.18.2 Switching off the electric drive system 179
6.19 Using the on-board computer 180
6.19.1 Using the diagnosis port 180
6.19.2 Charging the control panel battery 180
6.19.3 Using the riding light 181
6.19.4 Setting the brightness of indicators 181
6.19.5 Using the push assist system 181
6.19.6 Selecting the level of assistance 182
6.20 Using the brake 183
6.20.1 Use handbrake 183
6.20.2 Using the back-pedal brake 183
6.20.3 Using ABS 184
6.20.3.1 While riding 185
6.20.3.2 Reactivating the ABS 185
6.21 Gear shift 186
6.21.1 Switching the SHIMANO Rapidfire derailleur gears 186
6.22 Gear shift 187
6.22.1 Using the derailleur gears 187
6.22.2 Use SHIMANO hub gear 188
6.22.3 Using eShift 189
6.22.3.1 Using eShift with SHIMANO DI2 automatic hub gears 189
6.22.3.2 Using eShift with manual SHIMANO DI2 hub gears 189
6.22.3.3 Using eShift with SHIMANO DI2 automatic hub gears 189
6.22.4 Using an ENVIOLO gear shift gear 190
6.22.4.1 Switching gear manually 191
6.23 Parking 192
6.23.1 Screwing in the quickly adjustable stem 193
6.23.2 Activating the lock function 194
7 Cleaning, servicing and inspection
7.1 Before each ride 199

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Contents
7.1.1 Checking the guards 199
7.1.2 Checking the frame 199
7.1.3 Checking the fork 199
7.1.4 Checking the rear frame damper 199
7.1.5 Checking the pannier rack 199
7.1.6 Checking the mudguards 199
7.1.7 Check wheel concentricity 199
7.1.8 Checking the quick releases 199
7.1.9 Checking the suspension seat post 200
7.1.10 Checking the bell 200
7.1.11 Checking the handles 200
7.1.12 Checking the USB cover 200
7.1.13 Checking the riding light 200
7.1.14 Checking the brake 200
7.2 After each ride 201
7.2.1 Cleaning the riding light and reflectors 201
7.2.2 Cleaning the suspension fork 201
7.2.3 Maintaining the suspension fork 201
7.2.4 Cleaning the pedals 201
7.2.5 Cleaning the brake 201
7.2.6 Cleaning the suspension seat post 201
7.2.7 Cleaning the rear frame damper 201
7.3 Basic cleaning 202
7.3.1 Clean on-board computer and control panel 202
7.3.2 Cleaning the battery 202
7.3.3 Cleaning the motor 202
7.3.4 Clean Frame, fork, pannier rack, guards and kickstand 203
7.3.5 Cleaning the stem 203
7.3.6 Cleaning the handlebars 203
7.3.7 Clean handles 203
7.3.7.1 Cleaning leather handles 203
7.3.8 Cleaning the seat post 203
7.3.9 Cleaning the saddle 204
7.3.9.1 Cleaning the leather saddle 204
7.3.10 Cleaning the tyres 204
7.3.11 Cleaning the spokes and spoke nipples 204
7.3.12 Clean hub 204
7.3.13 Cleaning the switching elements 204
7.3.13.1 Cleaning the shifter 204
7.3.14 Clean cassette, chain wheels and front derailleur 204
7.3.15 Clean brake 205
7.3.15.1 Clean handbrake 205
7.3.16 Cleaning the brake disc 205
7.3.17 Cleaning the belt 205
7.3.18 Cleaning the chain 205
7.3.18.1 Clean chain, including all-round chain guard 205
7.4 Maintenance 206
7.4.1 Maintain frame 206
7.4.2 Maintain fork 206
7.4.3 Maintain pannier rack 207
7.4.4 Maintain mudguard 207
7.4.5 Servicing the kickstand 207
7.4.6 Maintaining the stem 207
7.4.7 Maintaining the handlebars 207
7.4.8 Maintaining the handles 207
7.4.8.1 Maintaining the rubber handles 207
7.4.8.2 Maintaining the leather handles 207
7.4.9 Maintaining the seat post 208
7.4.9.1 Maintaining the suspension seat post 208

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Contents
7.4.9.2 Maintaining the carbon seat post 208
7.4.10 Maintaining the rims 208
7.4.11 Maintaining the leather saddle 208
7.4.12 Maintaining the hub 208
7.4.13 Maintaining the spoke nipples 208
7.4.14 Maintaining the gear shift 209
7.4.14.1 Maintaining the rear derailleur articulated shafts and jockey wheel 209
7.4.14.2 Maintaining the shifter 209
7.4.15 Maintaining the pedals 209
7.4.16 Maintaining the chain 209
7.4.16.1 Maintaining the chain and all-round chain guard 210
7.4.17 Maintaining the battery 210
7.4.18 Maintaining the brake 210
7.4.18.1 Maintaining the handbrake 210
7.4.19 Lubricating the Eightpins seat post tube 210
7.5 Inspection 211
7.5.1 Checking the wheel 211
7.5.1.1 Checking tyre pressure 211
7.5.1.2 Checking the tyres 213
7.5.1.3 Checking the rims 214
7.5.1.4 Checking the nipple holes 214
7.5.1.5 Checking the nipple well 214
7.5.1.6 Checking the rim hooks 214
7.5.1.7 Checking the spokes 214
7.5.2 Checking the brake system 215
7.5.2.1 Checking the handbrake 215
7.5.2.2 Checking the hydraulic brake system 215
7.5.2.3 Checking the Bowden cables 215
7.5.2.4 Checking the disc brake 216
7.5.2.5 Checking the back-pedal brake 217
7.5.3 Checking the chain 218
7.5.4 Checking the chain tension 218
7.5.4.1 Check tension in derailleur gears 218
7.5.4.2 Check tension in hub gear 218
7.5.5 Checking the belt for wear 218
7.5.5.1 Rough check 218
7.5.5.2 Check 219
7.5.6 Checking the belt 220
7.5.7 Checking the belt for wear 220
7.5.8 Checking the belt sprockets for wear 220
7.5.9 Check belt tension 220
7.5.9.1 Gates Carbon Drive mobile app 221
7.5.9.2 Gates Krikit tension meter 221
7.5.9.3 ECO tension tester 222
7.5.10 Checking the riding light 223
7.5.11 Checking the stem 224
7.5.12 Checking the handlebars 224
7.5.13 Checking the saddle 224
7.5.14 Checking the seat post 224
7.5.15 Check pedal. 224
7.5.15.1 Checking the derailleur gears 224
7.5.15.2 Checking the hub gear 225
7.5.16 Check gear shift 225
7.5.16.1 Checking the electric gear shift 225
7.5.16.2 Check the mechanical gear shift 225
7.5.16.3 Checking the derailleur gears 226
7.5.17 Adjusting gear shift 226
7.5.17.1 Adjusting the ROHLOFF hub 226
7.5.18 Adjusting cable-operated gear shift, dual-cable 226

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Contents
7.5.19 Adjusting Bowden-cable-operated twist grip, dual-cable 227
7.5.20 Checking kickstand stability 227
8 Inspection and maintenance
8.1 Initial inspection 228
8.2 Major inspection 228
8.3 Component-specific maintenance 228
8.4 Carry out initial inspection 231
8.5 Perform major inspection 232
8.5.1 Inspect frame 239
8.5.1.1 Inspecting the carbon frame 239
8.5.2 Inspecting the pannier rack 239
8.5.3 Inspecting and maintaining the rear frame damper 239
8.5.4 Inspecting the gear hub 240
8.5.4.1 Adjusting the hub with cone bearing 240
8.5.5 Inspecting the stem 240
8.5.6 Inspect and grease steering headset 240
8.5.7 Inspecting the axle with quick release 241
8.5.8 Inspecting the fork 242
8.5.8.1 Inspecting the carbon suspension fork 242
8.5.8.2 Inspecting the suspension fork 242
8.5.9 Inspecting the seat post 243
8.5.9.1 Inspecting the carbon seat post 243
8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post 243
8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post 244
9 Troubleshooting, fault clearance and repair
9.1 Preventing pain 245
9.1.1 Sitting discomfort 246
9.1.2 Pain in hips 246
9.1.3 Backache 246
9.1.4 Pain in shoulders and nape of neck 247
9.1.5 Numb or aching hands 247
9.1.6 Pain in upper thigh 247
9.1.7 Knee pain 248
9.1.8 Pain in the foot 248
9.2 Drive system 249
9.2.1 Drive system or on-board computer does not start up 249
9.2.2 Errors in assistance function 250
9.2.3 Battery errors 251
9.2.4 Display screen errors 252
9.2.5 Lighting does not work 252
9.2.6 Problems with disc brakes 253
9.2.7 Problems with back-pedal brake 254
9.2.8 Problems with ABS 255
9.2.9 Problems with freewheel 256
9.2.10 Problem with SR SUNTOUR suspension fork 257
9.2.10.1 Rebound too fast 257
9.2.10.2 Rebounding too slowly 258
9.2.10.3 Suspension too soft on inclines 259
9.2.10.4 Excessively hard damping on bumps 260
9.2.11 Lighting does not work 261
9.2.12 Problems with the tyres 261
9.2.13 Problems with the seat post 261
9.3 Other errors 262
9.4 Repair 263
9.4.1 Original parts and lubricants 263
9.4.2 Repairing the frame 263