Bulls E-Core EVO AM 1 User manual

TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
20-18-1520
MY20B05-22_1.0_18.07.2019
Shimano 7000 operating instructions
E-Core Evo AM 1 27.5"

MY20B05-22_1.0_18.07.2019 1
Contents
Contents
1 About these operating instructions 4
1.1 Manufacturer 4
1.2 Type number and model 4
1.3 Identifying the operating instructions 4
1.4 Laws, standards and directives 5
1.5 Subject to change 5
1.6 Language 5
1.7 For your safety 5
1.7.1 Instruction, training and customer service 5
1.7.2 Basic safety instructions 5
1.7.3 Warnings 5
1.7.4 Safety markings 6
1.8 For your information 6
1.8.1 Instructions for actions 6
1.8.2 Language conventions 6
1.8.3 Information on the nameplate 7
1.9 Nameplate 8
2 Safety 9
2.1 General warnings 9
2.2 Toxic substances 10
2.3 Requirements for the rider 11
2.4 Protection for vulnerable groups 11
2.5 Data privacy 11
2.6 Personal protective equipment 11
2.7 Safety markings and safety instructions 11
2.8 Emergency 12
2.8.1 What to do in an emergency 12
2.8.2 First aid treatment 12
2.8.3 Fighting fire 12
2.8.4 Leaking fluids 13
2.8.4.1 Brake fluid 13
2.8.4.2 Oils and lubricants from the fork 13
2.8.4.3 Oils and lubricants from the rear frame
damper 13
3Overview 14
3.1 Description 15
3.1.1 Wheel and suspension 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.2.1 Steel suspension fork structure 16
3.1.2.2 Air suspension fork structure 16
3.1.2.3 Structure of the FOX rear frame damper 17
3.1.2.4 Structure of the Suntour rear frame
damper 17
3.1.3 Brake system 17
3.1.3.1 Rim brake 17
3.1.3.2 Disc brake 18
3.1.3.3 Back-pedal brake 18
3.1.4 Electric drive system 19
3.1.5 Rechargeable battery 19
3.1.6 Display 20
3.1.7 Operating elements 20
3.1.8 Riding light 21
3.1.9 Charger 21
3.2 Proper use 22
3.3 Improper use 23
3.4 Technical data 24
3.4.1 Pedelec 24
3.4.2 Rechargeable battery 24
3.4.3 Emissions 24
3.4.4 Tightening torque 24
3.5 Environmental requirements 25
3.6 Description of controls and screens 27
3.6.1 Handlebars 27
3.6.2 Battery level indicator 27
3.6.3 Display screen indicators 27
3.6.3.1 Gear indicator 27
3.6.3.2 System message 28
3.6.3.3 Warnings 28
3.6.3.4 Error messages 28
3.6.3.5 Battery level indicator 28
3.6.3.6 Journey information 28
3.6.3.7 Function display 28
3.6.3.8 Level of assistance 29
3.6.3.9 Displayed speed 29
4 Transporting and storing 30
4.1 Physical transport characteristics 30
4.1.1 Dimensions during transportation 30
4.1.2 Transport weight 30
4.1.3 Designated handles/lifting points 30
4.2 Transporting 30
4.2.1 Transporting the battery 31
4.2.2 Shipping the battery 31
4.2.3 Using the brake transport securing
system 31
4.3 Storing 31
4.3.1 Break in operation 32
4.3.1.1 Preparing a break in operation 32
4.3.1.2 Taking out of operation 32
5 Assembly 33
5.1 Required tools 33
5.2 Unpacking 33
5.2.1 Scope of delivery 33
5.3 Commissioning 34
5.3.1 Checking the battery 34
5.3.2 Installing the wheel in the Suntour fork 34
5.3.2.1 Installing the wheel with screw-on axle
(15 mm) 34
5.3.2.2 Installing the wheel with screw-on axle
(20 mm) 35
5.3.2.3 Installing the wheel with a quick release
axle 36

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Contents
5.3.3 Installing the wheel with a quick release 37
5.3.4 Installing the wheel in the FOX fork 38
5.3.4.1 Wheel with quick release (15 mm) 38
5.3.4.2 Adjusting the FOX quick release 39
5.3.4.3 Installing the wheel with Kabolt axles 39
5.3.4.4 Checking the stem and handlebars 39
5.3.5 Pedelec sale 40
6Operation 41
6.1 Risks and hazards 41
6.1.1 Tips for a greater range 42
6.1.2 Personal protective equipment 42
6.2 Error messages 43
6.3 Battery error message 43
6.4 Warning message 44
6.5 Error message screen 45
6.6 Before the first ride 46
6.6.1 Adjusting the saddle 46
6.6.1.1 Adjusting the saddle tilt 46
6.6.2 Determining the seat height 46
6.6.2.1 Adjusting the seat height with quick
release 46
6.6.2.2 Height-adjustable seat post 47
6.6.2.3 Adjusting the seat position 47
6.6.3 Adjusting the handlebars 48
6.6.3.1 Adjusting the stem 48
6.6.3.2 Adjusting the height of the handlebars 48
6.6.3.3 Turning the handlebars to the side 49
6.6.3.4 Checking the clamping force in quick
releases 49
6.6.3.5 Adjusting the quick release clamping
force 49
6.6.4 Adjusting the brake lever 49
6.6.4.1 Adjusting the pressure point on a
Magura brake lever 49
6.6.4.2 Adjusting the grip distance 50
6.6.4.3 Adjusting the grip distance on a
Magura brake lever 50
6.6.5 Adjusting the suspension of the
Suntour fork 51
6.6.5.1 Adjusting the negative deflection 51
6.6.5.2 Adjusting the air suspension fork
negative deflection 51
6.6.5.3 Adjusting the steel suspension fork
negative deflection 52
6.6.5.4 Adjusting the rebound 53
6.6.6 Adjusting the suspension of the
FOX fork 53
6.6.6.1 Adjusting the negative deflection 53
6.6.6.2 Adjusting the rebound 54
6.6.7 Setting the Suntour rear frame damper 55
6.6.7.1 Adjusting the negative deflection 55
6.6.7.2 Adjusting the rebound 55
6.6.7.3 Setting the compression 56
6.6.8 Setting the FOX rear frame damper 56
6.6.8.1 Adjusting the negative deflection 56
6.6.8.2 Adjusting the rebound 57
6.6.9 Retracting the brake linings 57
6.7 Accessories 58
6.7.1 Child seat 58
6.7.2 Bicycle trailers 59
6.7.3 Pannier rack 59
6.8 Before each ride 60
6.9 Check list before each ride 60
6.10 Using the kickstand 61
6.10.1 Raising the kickstand 61
6.10.1.1 Parking the pedelec 61
6.11 Using the pannier rack 61
6.12 Rechargeable battery 62
6.12.1 Side down tube battery 63
6.12.1.1 Inserting the battery 63
6.12.1.2 Removing the battery 63
6.12.2 Charging the battery 64
6.13 Electric drive system 66
6.13.1 Switching on the drive system 66
6.13.2 Switching off the drive system 66
6.13.3 Display 67
6.13.4 Using the riding light 67
6.13.5 Using the push assist system 67
6.13.5.1 Select WALK level of assistance 67
6.13.5.2 Switching on the push assist 67
6.13.5.3 Exit WALK level of assistance 68
6.13.5.4 Selecting the level of assistance 68
6.13.6 Switching the journey information 68
6.13.6.1 Deleting the journey information 69
6.13.6.2 Opening the settings menu 69
6.13.6.3 Closing the settings menu 69
6.13.6.4 Deleting the journey information 69
6.13.6.5 Setting the clock 70
6.13.6.6 Changing light 70
6.13.6.7 Changing the beep sound 70
6.13.6.8 Changing the units 70
6.13.6.9 Changing the language 71
6.13.6.10Changing the font colour 71
6.13.6.11Setting the gear shift 71
6.13.6.12Rear derailleur reset 71
6.14 Brake 72
6.14.1 Using the brake lever 73
6.14.2 Using the back-pedal brake 74
6.14.3 Using ABS 74
6.14.3.1 While riding 75
6.15 Suspension and damping 75
6.15.1 Adjusting the compression of the
Fox fork 75

MY20B05-22_1.0_18.07.2019 3
Contents
6.15.2 Adjusting the compression of the Fox
damper 76
6.15.3 Adjusting the compression of the
Suntour fork 76
6.15.4 Adjusting the compression of a
Suntour damper 76
6.15.5 Adjusting the rebound in a Rock
Shox damper 77
6.15.6 Adjusting the compression in a
Rock Shox damper 77
6.16 Gear shift 78
6.16.1 Using the derailleur gears 78
6.16.2 Using the hub gear 78
6.16.3 Use eShift 79
6.16.3.1 eShift with Shimano DI2 automatic
hub gears 79
6.16.3.2 eShift with manual Shimano DI2
hub gears 79
6.16.3.3 eShift with Shimano DI2 automatic
hub gears 79
6.16.3.4 eShift with NuVinci H|Sync/enviolo
with Optimized H|Sync 80
6.16.3.5 eShift with Rohloff E-14 Speedhub
500/14 80
7 Cleaning and servicing 81
7.1 Cleaning after each ride 81
7.1.1 Cleaning the suspension fork 81
7.1.2 Cleaning the rear frame damper 81
7.1.3 Cleaning the pedals 81
7.2 Basic cleaning 82
7.2.1 Cleaning the frame 82
7.2.2 Cleaning the stem 82
7.2.3 Cleaning the rear frame damper 82
7.2.4 Cleaning the wheel 82
7.2.5 Cleaning the drive elements 82
7.2.6 Cleaning the chain 83
7.2.7 Cleaning the battery 83
7.2.8 Cleaning the display 83
7.2.9 Cleaning the drive unit 83
7.2.10 Cleaning the brake 84
7.3 Servicing 84
7.3.1 Servicing the frame 84
7.3.2 Servicing the stem 84
7.3.3 Servicing the fork 84
7.3.4 Servicing the drive elements 84
7.3.5 Servicing the pedals 84
7.3.6 Servicing the chain 84
7.3.7 Servicing the drive elements 84
7.4 Maintenance 85
7.4.1 Wheel 85
7.4.2 Checking the tyres 85
7.4.3 Checking the rims 85
7.4.4 Checking and adjusting the tyre pressure
85
7.4.4.1 Dunlop valve 85
7.4.4.2 Presta valve 86
7.4.4.3 Schrader valve 86
7.4.5 Brake system 86
7.4.6 Checking the brake linings for wear 86
7.4.7 Checking the pressure point 86
7.4.8 Checking the brake discs for wear 86
7.4.9 Electrical cables and brake cables 87
7.4.10 Gear shift 87
7.4.11 Stem 87
7.4.12 USB port 87
7.4.13 Checking the belt and chain tension 87
7.5 Maintenance message 87
8 Maintenance 88
8.1 Axle with quick release 89
8.1.1 Checking the quick release 89
8.2 Adjusting the gear shift 89
8.2.1 Cable-operated gear shift, single-cable 90
8.2.2 Cable-operated gear shift, dual-cable 90
8.2.3 Cable-operated twist grip, dual-cable 90
9 Troubleshooting, fault clearance
and repair 91
9.1 Troubleshooting and fault clearance 91
9.1.1 The drive system or display do not
start up 91
9.1.2 Error messages 91
9.2 Assistance function 92
9.3 Rechargeable battery 93
9.4 Lighting 94
9.5 Display 94
9.6 Miscellaneous 95
9.7 Repair 95
9.7.1 Use original parts and lubricants only 95
9.7.2 Replacing the lighting 95
9.7.3 Setting the headlight 95
10 Recycling and disposal 96
11 Documents 97
11.1 Parts list 97
11.2 Assembly report 98
11.3 Maintenance log 100
11.4 RED certification 103
11.5 Documented evidence of
conformity with Directive 2014/35/EU 108
12 Keyword index 110
13 Glossary 111
Appendix 114
I. Translation of the original EC
declaration of conformity 114

MY20B05-22_1.0_18.07.2019 4
About these operating instructions
1 About these operating instructions
Thank you for your trust!
BULLS pedelecs are sporting equipment of the
highest quality – you have made a good choice.
Your specialist dealer has advised you and
assembled your product. Whether maintenance,
inspection, conversion or repair, your specialist
dealer will also be happy to assist you in the
future.
You receive these operating instructions with your
new pedelec. Please take a little 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 BULLS 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 designed for the
rider and the operator of the pedelec to ensure
that non-professionals can use the pedelec safely.
You can download the operating instructions onto
your mobile phone at the following address, so
that you can use them when you are out riding:
www.bulls.de/service/
downloads
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]
Internet: www.zeg.de
1.2 Type number and model
The operating instructions are an integral part of
pedelecs with the following type numbers:
1.3 Identifying the operating
instructions
You will find the operating instructions
identification number at the bottom left-hand side
of each page. The identification number consists
of the document number, the version number and
the release date.
Notice
The operating instructions are not a substitute for
personal instruction by the supplying specialist
dealer.
The 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.
Instructions for the specialist dealer are highlighted in grey and
marked with a symbol. Specialist dealers have specialist
training and qualifications and are thus able to identify risks and
prevent hazards which may arise during maintenance, servicing
and repairs on the pedelec. Information for specialist staff does
not require non-professionals to take any action.
Type no. Model Pedelec type
20-18-1520 Bulls E-Core EVO AM 1 Mountain bike
Table 1: Type number, model and pedelec type
Identification number MY20B05-22_1.0_18.07.2019
Table 2: Identification number

MY20B05-22_1.0_18.07.2019 5
About these operating instructions
1.4 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/DIS 20607:2018 Safety of machinery –
Instruction handbook – General drafting
principles
• EN 15194:2018 Cycles – Electrically power
assisted cycles – pedelec bicycles
• EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
• EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
1.5 Subject to change
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes will be included in a new issue
of the operating instructions.
You will find any modifications to these operating
instructions:
www.bulls.de/service/downloads
1.6 Language
The original operating instructions are written in
German. A translation is not valid without the
original operating instructions.
1.7 For your safety
The pedelec's safety concept comprises four
elements:
• rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer
• the section on general safety
• the warnings in these operating instructions
• the safety markings on the nameplate and the
pedelec.
1.7.1 Instruction, training and customer
service
The supplying specialist dealer will provide
customer service. Contact details can be found on
the back page of these operating instructions and
on the data sheet. If you are unable to contact
your specialist dealer, you will find other specialist
dealers online at www.bulls.de.
The rider or the operator of the pedelec will be
instructed on the pedelec's functions in person
when the supplying specialist dealer hands over
the pedelec, if not before. In particular, this
instruction will cover the pedelec's electrical
functions and correct use of the charger.
Each rider to whom this bicycle is provided must
receive instruction on the pedelec's functions. A
printed copy of these operating instructions must
be provided to each rider, who must take note of
and observe them.
1.7.2 Basic safety instructions
These operating instructions explains all general
safety instructions in Section 2.
1.7.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating
instructions are indicated as follows:
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. Low-risk
hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!

MY20B05-22_1.0_18.07.2019 6
About these operating instructions
1.7.4 Safety markings
The following safety markings are used on the
pedelec's nameplates:
1.8 For your information
1.8.1 Instructions for actions
Instructions for actions are structured in
accordance with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)
1.8.2 Language conventions
The pedelec described in these operating
instructions may be equipped with alternative
equipment. The pedelec equipment is defined by
its respective type number. Where applicable, the
word Alternative beneath the heading indicates
alternatively used components. The following terms
are used for better legibility:
The following conventions are used in these
operating instructions:
General warning
Adhere to the instructions for use
Table 3: Meaning of safety markings Term Meaning
Operating
instructions
Original operating
instructions or translation
of the original operating
instructions
Pedelec Electric motor driven cycle
Motor Drive motor
Convention Use
Italics Glossary terms
SPACED Indicators on the display
screen
[Example, page
numbering]
Cross references
• Bulleted lists

MY20B05-22_1.0_18.07.2019 7
About these operating instructions
1.8.3 Information on the nameplate
Alongside the warnings, product nameplates also
contain other important information about the
pedelec:
Read the instructions
Separate collection of
electrical and electronic
devices
Separate collection of
batteries
Must not be thrown into fire
(burning prohibited)
Battery must not be opened
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 4: Relevance of safety instructions
max. 50°C

MY20B05-22_1.0_18.07.2019 8
About these operating instructions
1.9 Nameplate
The nameplate is situated on the frame. You will
find the precise position of the nameplate in Figure 2.
You will find thirteen pieces of information on the
nameplate.
Figure 1: Nameplate, example
No. Designation Description
1 CE marking 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 this address. You can find more information in
Section 1.1.
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 further information in
Section 1.9.1.
4 Maximum continuous power The maximum continuous power is the maximum power for the electric motor output shaft
during 30 minutes.
5 Permitted total weight The permitted total weight is the weight of the fully assembled pedelec with the rider and
baggage.
6Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2019 to July 2020.
7 Pedelec type You can find further information in Section 1.9.3.
8 Safety markings You can find more information in Section 2.6.
9 Disposal instructions You can find more information in Section 9.
10 Area of use You can find further information in Section 1.9.4.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version and is not always identical with the year of manufacture.
The year of manufacture may be before the model year in some cases. If no technical
modifications are introduced to the series, production may continue of pedelecs from a
previous model year.
12 Weight of the ready-to-ride pedelec The indicated weight for a ready-to-ride pedelec refers to the weight of a pedelec at the
time of sale. The weight of each additional accessory must be added to this weight
13 Shut-off speed Speed reached by the pedelec at the moment when the current has dropped to zero or to
the no load current value.
ZEG Zweirad-Einkaufs-
Genossenschaft eG
Longericher Str. 2
50739 Köln, Germany
Typ:
20-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2019 / MJ 2020
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11

MY20B05-22_1.0_18.07.2019 9
Safety
2 Safety
2.1 General warnings
Risk of fire and explosion due to faulty battery
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BOSCH Systems
pedelecs only. This is the only way that the
battery will be protected from dangerous
overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
WARNING
!
Electric shock in case of damage
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.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never immerse the battery in water.
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
CAUTION
!

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Safety
2.2 Toxic substances
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. The battery may self-ignite and explode.
Protect the battery against heat.
Never expose the battery to sustained direct
sunlight.
Fire 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 the charger on a highly flammable
surface (e.g. paper, carpet etc.).
Never cover the charger during the charging
process.
Never leave the battery unattended during
charging.
Electric shock caused by penetration by
water
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
Notice
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 from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
CAUTION
!
Intoxication from suspension oil
Suspension oil in the rear frame damper is toxic to
the touch, irritates respiratory tracts and causes
cancer, sterility and mutation in germ cells.
Never disassemble the rear frame damper.
Never allow suspension oil to come into
contact with the skin.
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from damaged or
faulty batteries. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Ventilate with fresh air and consult a doctor if
you suffer any pain or discomfort.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
Hazard for the environment due to leaking
brake fluid
The brake system contains a toxic, environmentally
harmful brake fluid. Such fluids will contaminate if
they enter the sewers or groundwater.
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
WARNING
!
CAUTION
!

MY20B05-22_1.0_18.07.2019 11
Safety
2.3 Requirements for the rider
If there are no legal requirements for riders of
electrically power-assisted cycles, we recommend
that the rider should be a minimum 15 years of
age and have experience with muscle-powered
bicycles.
The rider's physical and mental abilities must be
adequate to use a muscle-powered pedelec.
2.4 Protection for vulnerable groups
You must keep batteries and charger away from
children and people with reduced physical,
sensory or mental capabilities or lacking in
experience and knowledge.
If minors are to use the pedelec, comprehensive
instruction should be provided by or in the
presence of the legal guardians. Supervised use
should also be scheduled until it is certain that the
pedelec is being used as per these operating
instructions.
2.5 Data privacy
During maintenance, the pedelec is connected to
the diagnosis tool and data is transferred to Bosch
Pedelec Systems (Robert Bosch GmbH) about the
use of electric drive components to help improve
the product. You will find more information on the
Bosch Pedelec website
https://www.bosch-ebike.com/en/
2.6 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting clothing for
bicycles.
2.7 Safety markings and safety
instructions
The nameplate contains the following safety
markings and safety instructions:
Environmental hazard posed by oil and
lubricants from the fork
The fork contains toxic, environmentally harmful oils
and lubricants. Such fluids will contaminate if they
enter the sewers or groundwater.
The fork must be repaired immediately if oils
and lubricants are leaking out. Contact your
specialist dealer about repair.
Dispose of leaked oils and lubricants in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
Environmental hazard posed by oil and
lubricants from rear frame damper
The rear frame damper contains toxic and
environmentally harmful oils and lubricants. Such
fluids
will contaminate if they enter the sewers or
groundwater.
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
CAUTION
!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 5: Meaning of safety markings

MY20B05-22_1.0_18.07.2019 12
Safety
2.8 Emergency
2.8.1 What to do in an emergency
In the event of a hazard or danger 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.
2.8.2 First aid treatment
Symptoms which are caused by combustion
gases or leaking fluids require medical attention.
After inhalation
Vapours may emit if the battery is damaged or
used improperly Get into fresh air and consult a
doctor if you suffer any pain or discomfort. The
vapours may cause respiratory tract irritation.
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 or abnormalities.
After contact with eyes
Rinse eyes with plenty of water for at least
15 minutes. Protect unaffected eye. Seek medical
advice immediately.
After swallowing
Drink plenty of milk or water and induce vomiting.
Seek medical advice immediately.
2.8.3 Fighting fire
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Keep your distance if the battery becomes
deformed or starts to emit smoke.
Evacuate everyone from the immediate area of
the fire.
Contact 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.
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 6: Relevance of safety instructions
max. 50°C
Intoxication
Inhaling vapours can cause
intoxication.
Stand on the side of the fire
where the wind is coming from.
Use breathing apparatus if
possible.
WARNING
!

MY20B05-22_1.0_18.07.2019 13
Safety
2.8.4 Leaking fluids
2.8.4.1 Brake fluid
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.2 Oils and lubricants from the fork
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.3 Oils and lubricants 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. Ask a
specialist dealer for more information.

MY20B05-22_1.0_18.07.2019 14
Overview
3Overview
Figure 2: Pedelec viewed from the right, example
1Front wheel
2Fork
3Handlebars
4Stem
5Frame
6 Seat post
7 Saddle
8 Rear wheel
9 Chain
10 Frame number
11 Damper
12 Battery and nameplate
1
2
3
4
5
6
7
8
91011
12

MY20B05-22_1.0_18.07.2019 15
Overview
3.1 Description
3.1.1 Wheel and suspension
Figure 3: Components of the wheel, example of front
wheel
1 Tyre
2 Rim
3 Suspension fork head with setting wheel
4 Shock absorber
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of the shock absorber
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 either has a conventional Dunlop
valve, a Presta valve or a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series. A suspension fork is based either on a
steel spring or air suspension. Unlike a rigid fork, a
suspension fork has two functions which improve
floor contact and comfort: suspension and damping.
Figure 4: Pedelec without suspension (1) and with
suspension (2) when riding over an obstacle
The suspension prevents an impact, such as one
caused by a stone lying in the bike'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. The compression
can be disabled so that a suspension fork reacts
like a rigid fork. The switch to disable the fork is
called a remote lockout.
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.
1
2
4
5
8
7
3
9
6
12

MY20B05-22_1.0_18.07.2019 16
Overview
3.1.2.1 Steel suspension fork structure
Figure 5: Example showing Suntour fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6). Other elements: the compression
setting (2), crown (3), Q-Loc (5), dust seal (6),
fork end for quick release (7), stanchion (8) and
spring (9)
3.1.2.2 Air suspension fork structure
The pedelec's fork features both air suspension and
a compression damper plus a rebound damper in
some cases.
Figure 6: Example showing Yari fork
You can see the following components in the
diagram: Air valve (1), valve cap (2) fork lock (3),
quick release (4) and rebound damper
adjuster (5) and the assembly groups: Air
suspension fork (A), compression damper
assembly group (B) and rebound damper
assembly group (C)
1
1
2
3
4
5
6
7
8
7
A
B
C
1
2
3
4
5
A
B
C

MY20B05-22_1.0_18.07.2019 17
Overview
3.1.2.3 Structure of the FOX rear frame damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 7: Example showing FOX rear frame damper
1 Guide rod eye
2Air valve
3 Setting wheel
4 Lever
5 Air chamber
6O-ring
3.1.2.4 Structure of the Suntour rear frame
damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 8: Example showing Suntour rear frame damper
1 Upper eye
2.1 Total damper length
2.2 SAG
3 Lower eye
4O-ring
5 Sleeve
6 Damper unit
7 IFP (internal floating piston)
8Air valve
9 Air chamber
10 Lockout lever
11 Rebound lever
3.1.3 Brake system
The pedelec's brake system comprises either a
hydraulic:
• rim brake on the front and rear wheels
• disc brake on the front and rear wheels or
• a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the pedelec to
a halt quickly and safely in the event of an
emergency.
3.1.3.1 Rim brake
Figure 9: Rim brake components with details; Magura
HS22 used as an example
1 Rear wheel rim brake
2 Brake booster
3 Brake lining
4Handlebars with brake lever
5 Front wheel rim brake
The rim brake stops the wheel moving when the
rider pulls the brake lever, causing two brake
linings, positioned opposite one another, to be
pressed onto the rims.
25-30%
1
2
4
3
1
2.2
3
4
5
6
78
910
11
2.1
1
2
3
4
5

MY20B05-22_1.0_18.07.2019 18
Overview
The hydraulic rim brake features a locking lever.
Figure 10: Rim brake locking lever, closed (1) and open (2)
3.1.3.2 Disc brake
Figure 11: Pedelec brake system with a disc brake –
example
1Brake disc
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 pulled to increase brake
pressure. The brake fluid is used to transfer
pressure through the brake lines 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 pulled, the brake linings are
pressed against the brake disc and the wheel
movement is decelerated until it comes to a stop.
3.1.3.3 Back-pedal brake
Figure 12: Pedelec brake system with a back-pedal brake
– example
1 Rear wheel rim brake
2Handlebars with brake lever
3 Front wheel rim brake
4Pedal
5 Back-pedal brake
The back-pedal brake stops the movement of the
rear wheel when the rider pedals in the opposite
direction to the direction of travel.
The rim brake locking lever is not marked with any lettering.
Only a specialist dealer may set the rim brake locking lever
1
2
3
4
5
5
2
3
4
1

MY20B05-22_1.0_18.07.2019 19
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 13: 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.
The electric drive system comprises the following
components:
Figure 14: Diagram of electric drive system
1 Display
2 Connecting cable
3 Assistance lever
4 Charger
5 Rechargeable battery
6 Chain tensioner
7 Drive unit cover
8Drive unit
9 Rear derailleur (DI2)
10 Front chainring
11 Crank
12 Shifter
13 Rechargeable battery
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the pedalling motion
of the rider. The motor force is determined by the
set level of assistance.
The pedelec does not have a separate emergency
stop or emergency shut-off button.
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.
A push assist system can be activated. The push
assist continues to drive the pedelec at walking
speed as long as the rider pushes the long
assistance lever on the handlebars. The speed
can be a maximum of 6 km/h in this case. The
drive stops when the long assistance lever is
released.
3.1.5 Rechargeable battery
The lithium ion 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. 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 also
switches to sleep mode for self-protection when
not used for a longer period.
5
2
4
1
65
4
12
1
3
2
9
10
7
8
11 13