Classified POWERSHIFT HUB User manual

USER MANUAL
POWERSHIFT HUB

© Copyright Classified Cycling
This document is a translation of the originalDutchuser manual.
All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system or translated into any language or computer language in any
form or by any means, electronic, mechanical, optical, chemical, manual or otherwise, without the prior written permission of Classified Cycling BV. Classified Cycling
BV reserves the right to change any information in this document without notice. These changes will be incorporated in new editions of this manual or in additional
documents and publications.
Product names or trademarks of other companies are used for identification purposes only and are the property of their respective owners.
Classified Cycling BV
Damplein 23 [email protected]
2060 Antwerpen https://classified-cycling.cc
Doc. nr. classified_powershift_hub_en
Version 20230314

Classified Powershift hub
Content
1. Introduction 5
1.1 Symbols used............................................................................................................................................................................................................ 5
1.2 Abbreviations.............................................................................................................................................................................................................5
1.3 Intended use.............................................................................................................................................................................................................. 5
1.4 Prohibited use...........................................................................................................................................................................................................6
1.5 Type designation.....................................................................................................................................................................................................7
2. Safety 9
2.1 Safety precautions................................................................................................................................................................................................. 9
2.2 Hazardous substances........................................................................................................................................................................................ 9
3. Description 10
3.1 ITS and ETS.............................................................................................................................................................................................................10
3.2 Part names................................................................................................................................................................................................................10
4. Principles of operation 14
4.1 The operation of the Classified Powershift hub............................................................................................................................... 14
5. Configuration 16
5.1 Selecting and preparing the correct smart thru axle.................................................................................................................... 16
5.2 Identifying the bicycle frame type (postmount - flatmount).....................................................................................................21
5.3 Selecting and installing the correct torque support for a flatmount frame......................................................................21
5.4 Overview of options for torque supports and spacers for a flatmount frame................................................................24
5.5 Selecting and installing the correct torque support for a postmount frame.................................................................. 25
6. Storage and transport 27
6.1 Storing and transporting the Classified Powershift hub............................................................................................................. 27
7. Assembly and installation 28
7.1 What is included?.................................................................................................................................................................................................28
7.2 Replacing a wheel with a Classified Powershift hub..................................................................................................................... 28
7.3 Bluetooth® pairing (dropbar handlebar unit)......................................................................................................................................30
7.4 Bluetooth® pairing (flatbar handlebar unit)..........................................................................................................................................31
8. Initial use 32
8.1 Initial use of the dropbar handlebar unit.............................................................................................................................................. 32
8.2 Initial use of the flatbar handlebar unit................................................................................................................................................. 32
EN
3

Classified Powershift hub
EN
9. Operation 34
9.1 Operation...................................................................................................................................................................................................................34
10. Maintenance 35
10.1 Maintenance schedule...................................................................................................................................................................................... 35
10.2 Checking the Powershift hub.......................................................................................................................................................................35
10.3 Tools required.........................................................................................................................................................................................................35
10.4 Check the battery status of the thru axle........................................................................................................................................... 35
10.5 Check the battery status of the dropbar handlebar unit........................................................................................................... 36
10.6 Check the battery status of the flatbar handlebar unit...............................................................................................................37
10.7 Replacing the battery of the dropbar handlebar unit................................................................................................................... 37
10.8 Recharging the battery of the flatbar handlebar unit...................................................................................................................38
10.9 Recharging the battery of the smart thru axle.................................................................................................................................39
10.10 Cleaning the Classified Powershift hub................................................................................................................................................ 40
10.11 Troubleshooting....................................................................................................................................................................................................40
11. Recycling 44
11.1 Recycling the Classified Powershift hub.............................................................................................................................................. 44
12. Appendices 45
12.1 Warranty.....................................................................................................................................................................................................................45
12.2 EC Declaration.......................................................................................................................................................................................................45
12.3 FCC and ISED declaration..............................................................................................................................................................................45
12.4 ICASA label..............................................................................................................................................................................................................46
12.5 Spare parts...............................................................................................................................................................................................................46
 Index 47
4

Classified Powershift hub
1. Introduction
1.1 Symbols used
This user manual uses the following symbols:
TIP
Provides the user with suggestions and advice to perform a procedure more easily or conveniently.
NOTE
A general comment which may oer an increased economic utility.
ENVIRONMENT
Guidelines that must be followed when using hazardous substances and when recycling products and materials.
CAUTION
Indicates a hazardous situation which, if the safety instructions are not followed, may lead to minor or moderate
injury and/or damage to the product or the environment.
WARNING
Indicates a hazardous situation which, if the safety instructions are not followed, may lead to serious injury or
death, and/or serious damage to the product or the environment.
DANGER
Indicates a hazardous situation which, if the safety instructions are not followed, will lead to serious injury or
death.
1.2 Abbreviations
Abbreviation More details
O.L.D. Over-Lock-nut Dimension
The hub distance is measured from the outside of the end caps.
ITS Internal Torque Support
In the ITS version of the hub and thru axle, the frame must have a specific Classified insert on
the rear brake side. The hub supports the torque via the thru axle in the Classified insert. The
Classified insert must be provided by the manufacturer.
ETS External Torque Support
In the ETS version of the Powershift hub and smart thru axle, the torque is transmitted to the
frame via a Classified torque support.
1.3 Intended use
The product is a wirelessly shiftable 2 speed Powershift hub which can be integrated in road and gravel bikes and
mountain bikes.
The product may only be used on a bicycle:
EN
1. Introduction
1.1 Symbols used 5

Classified Powershift hub
EN
•with compatible chains. For optimal shifting performance, the following chains are recommended:
•Chains for cassettes with 11 speeds: Shimano CN-HG601-11, CN-HG701-11, CN-HG901-11, KMC X11, DLC11
•Chains for cassettes with 12 speeds: Shimano CN-M8100-12, CN-M7100-12, SRAM CN-FRC-D1, KMC X12, DLC12
•Chains for cassettes with 13 speeds: Campagnolo C13
Other chains may negatively aect shifting quality.
•combined with dropbar handlebars equipped with a hole for wiring near to the end. Example: PRO Vibe Alloy and
PRO Vibe Carbon
•combined with flatbar handlebars with outer diameter of 22.2 mm
•with brake discs
•with flatmount and postmount frames
•with a frame having an installation width of 142 mm or 148 mm for the rear wheel
•in ambient temperatures (while in use) between -15 °C and +50 °C
•compatible with the Classified handlebar switches
•with a frame equipped with internal torque support or using external torque support (which has been approved for
that specific frame)
WARNING
Requirements for a 142 mm hub:
•Front chain plate with at least 40 teeth for all applications
•Maximum 11-34T cassette for electric bicycles
•Maximum 11-40T cassette for non-electric bicycles
•Maximum 70 Nm mid-drive motor
WARNING
Requirements for a 148 mm hub:
•Front chain plate with at least 30 teeth for all applications
•Maximum 11-40T cassette for all applications
1.4 Prohibited use
It is prohibited to use the product for any other purpose than those indicated in this manual, the safety indications or
other safety documents accompanying the product.
Any modification to the product may aect its safety and warranty!
It is prohibited to use any other combinations than those described in the intended use.
It is prohibited to drill holes in the handlebar for the wiring. This will void the warranty and may lead to injuries or death.
It is prohibited to open the smart thru axle or the Powershift hub for any purpose not described in the maintenance
section.
It is prohibited to install parts on the product which have not been approved by Classified Cycling. These may:
•aect or prevent the operation of the product,
•endanger the safety of the user or other people,
•shorten the life of the product,
•void the compliance with the CE directives.
1. Introduction
61.4 Prohibited use

Classified Powershift hub
1.5 Type designation
The various Classified components are labelled with a serial number. The handlebar unit and the Powershift hub are also
marked with a QR code. Scan the QR code on the registration card in order to register the component.
Fig. 1: Dropbar handlebar unit label
Fig. 2: Flatbar handlebar unit label
Fig. 3: Smart thru axle label
EN
1. Introduction
1.5 Type designation 7

Classified Powershift hub
EN
Fig. 4: Powershift hub label
1. Introduction
81.5 Type designation

Classified Powershift hub
2. Safety
2.1 Safety precautions
CAUTION
Read the user manual before using the product! Retain this user manual for future reference. Also retain the
accessories and tools included for future use.
WARNING
Never open or disassemble the Classified Powershift hub. Damage to the Classified Powershift hub and serious
injuries may occur. Furthermore, the warranty will be voided.
WARNING
As well as the intended and prohibited use, the maintenance requirements must be complied with. Failure to
comply correctly may result in the Classified Powershift hub or the chain breaking. This may cause serious
injuries.
WARNING
The Classified Powershift hub can withstand riding in rainy weather conditions. However, do not submerge the
Classified Powershift hub in water and do not clean it using a high pressure cleaner. Damage to the Classified
Powershift hub may occur, leading to serious injuries as a result of defective operation.
2.2 Hazardous substances
The product contains:
•A replaceable button cell battery CR1632 (only in the dropbar handlebar unit)
•A rechargeable lithium-ion battery with a capacity of 320 mAh (in the smart thru axle)
•A rechargeable lithium-ion battery with a capacity of 40 mAh in the flatbar handlebar unit
The lubricant used to lubricate the chain, and hence indirectly lubricating the cassette, is a hazardous substance.
Carefully read the lubricant's safety instructions.
EN
2. Safety
2.1 Safety precautions 9

Classified Powershift hub
EN
3. Description
3.1 ITS and ETS
For each internal hub gear, the torque must be supported on the frame. There are 2 ways to do this for 142 mm hubs: ITS
and ETS. 148 mm hubs can only be combined with ETS.
ITS (Internal Torque Support)
In the ITS version of the hub and thru axle, the frame must have a specific Classified insert on the rear brake side. The
hub supports the torque via the smart thru axle in the Classified insert. The Classified insert must be provided by the
manufacturer.
ETS (External Torque Support)
In the ETS version of the Powershift hub and smart thru axle, the torque is transmitted to the frame via a Classified
torque support. The torque support must be chosen based on the frame type and brake type.
See also
Selecting and installing the correct torque support for a flatmount frame on page 21
Selecting and installing the correct torque support for a postmount frame on page 25
3.2 Part names
Fig. 5: Parts
3. Description
10 3.1 ITS and ETS

Classified Powershift hub
No. Part Variant
no.
Variant Explanation
1.1 Wireless dropbar
handlebar unit
The wireless dropbar handlebar unit is installed
into the left-hand side of the handlebar and
is operated by a shifter or satellite buttons
compatible with Classified. The dropbar
handlebar unit is powered by a battery.
1 Handlebar unit
1.2 Wireless flatbar
handlebar unit
The wireless flatbar handlebar unit can be
mounted on the left or right side of the right
handlebar. The module is powered by a battery
and charged by a pogo connector.
2 Smart thru axle 2.1 - The smart thru axle receives the wireless shift
signal from the handlebar unit and triggers
the Powershift hub using contactless energy
transfer. The smart thru axle is equipped with a
rechargeable battery. The axle diameter is 12 mm.
Dierent lengths are available for a perfect fit to
any frame. Various threaded ends are available to
fit the frame dropout. The threaded ends come in
various thread sizes and lengths.
3.1 Without torque
support (only with
ITS)
This end cap seals the Powershift hub and
interfaces to the inside of the frame.
3.2 With flatmount torque
support
This end cap seals the Powershift hub and
provides flatmount torque support. Dierent
torque supports are available for a perfect fit to
any frame.
3 Brake-side end cap
3.3 With postmount
torque support
This end cap seals the Powershift hub and
provides postmount torque support. Dierent
torque supports are available for a perfect fit to
any frame.
4 Hubshell lock ring 4.1 - The hubshell lock ring ensures that the hubshell
is fixed to the Powershift hub.
5 Brake disc lock ring 5.1 - The brake disc lock ring fixes the center lock
brake disc to the Classified hubshell.
6 Hubshell 6.1 Hubshell 142 The hubshell is attached to the rim by spokes.
You can equip multiple rims with a Classified
hubshell and use them in combination with a
single 142 Classified Powershift hub.
NOTE
Combination with a dierent Classified
Powershift hub variant is not possible.
EN
3. Description
3.2 Part names 11

Classified Powershift hub
EN
No. Part Variant
no.
Variant Explanation
6.2 Hubshell 148 The hubshell is attached to the rim by spokes.
You can equip multiple rims with a Classified
hubshell and use them in combination with a
single 148 Classified Powershift hub.
NOTE
Combination with a dierent Classified
Powershift hub variant is not possible.
7.1 Powershift hub 142
cassette interface
The Powershift hub 142 cassette interface
contains the shifting mechanism and is controlled
electronically. This hub is designed specifically
for hubs with 142 mm O.L.D. and a 12 mm thru
axle. The hub does not contain a battery and gets
its shifting power from the smart thru axle. This
hub can only be used with Classified cassettes.
7.2 Powershift hub 142 9-
spline interface
The Powershift hub 142 9-spline interface
contains the shifting mechanism and is operated
electronically. This hub is designed specifically
for hubs with 142 mm O.L.D. and a 12 mm thru
axle. The hub does not contain a battery and
gets its shifting power from the smart thru axle.
The hub can be used with standard 9-spline belt
sprockets or chainrings supplied by third parties.
NOTE
It is NOT possible to mount a standard
cassette on this interface!
7.3 Powershift hub 148
cassette interface
The Powershift hub 148 cassette interface
contains the shifting mechanism and is controlled
electronically. This hub is designed specifically
for hubs with 148 mm O.L.D. and a 12 mm thru
axle. The hub does not contain a battery and gets
its shifting power from the smart thru axle. This
hub can only be used with Classified cassettes.
7 Powershift hub
7.4 Powershift hub 148 9-
spline interface
The Powershift hub 148 9-spline interface
contains the shifting mechanism and is operated
electronically. This hub is designed specifically
for hubs with 148 mm O.L.D. and a 12 mm thru
axle. The hub does not contain a battery and
gets its shifting power from the smart thru axle.
The hub can be used with standard 9-spline belt
sprockets or chainrings supplied by third parties.
NOTE
It is NOT possible to mount a standard
cassette on this interface!
3. Description
12 3.2 Part names

Classified Powershift hub
No. Part Variant
no.
Variant Explanation
8.1 Cassette center
washer
This center washer ensures that the cassette
seamlessly connects to the Powershift hub.
8 Center washer
8.2 9-spline spacer kit The 9-spline spacer kit ensures that the 9-spline
sprocket connects seamlessly to the Powershift
hub. The spacer kit contains spacers in various
thicknesses to achieve the optimal belt / chain
line.
9.1 Classified cassette The Classified cassette is mounted on the
Powershift hub with cassette interface. Various
cassettes are available.
9 Cassette / sprocket
9.2 9-spline sprocket The 9-spline sprocket is mounted on a Powershift
hub with 9-spline interface. Various 9-spline
sprockets are available.
10.1 Cassette lock ring The cassette lock ring fixes the cassette to the
Powershift hub.
Color: black
10 Lock ring
10.2 9-spline sprocket lock
ring
The 9-spline sprocket lock ring attaches the 9-
spring sprocket to the Powershift hub.
Color: silver
EN
3. Description
3.2 Part names 13

Classified Powershift hub
EN
4. Principles of operation
4.1 The operation of the Classified Powershift hub
Through a compatible shifter or satellite button, a shifting command is sent to the handlebar unit. The handlebar unit
wirelessly transmits the shifting command to the smart thru axle using Bluetooth®. The smart thru axle transfers the
power needed for shifting and the shifting command to the Powershift hub. The shifting takes place internally within the
Powershift hub.
If the smart thru axle does not move or receive a shifting command for 20 minutes, it enters sleep mode. When the
smart thru axle is in sleep mode and the handlebar unit sends a shifting command, it takes a maximum of 5 seconds
for the smart thru axle to wake up from sleep mode. Once that happens, you can start shifting with the Powershift hub
again. As long as the smart thru axle is not in sleep mode, shifting will happen immediately when a shifting command is
transmitted.
The smart thru axle transmits your current gear ratio and battery status to your GPS bike computer (not included) using
ANT+. Consult the handbook of your bike computer for more information.
The Powershift hub has two gears:
•A 1:1 ratio where the speed of the cassette is equal to the speed of the wheel. This is similar to the large chainring on
a traditional 2x.
•A 0.686 ratio (reduction ratio), where the speed of the wheel is lower than the speed of the cassette. This is similar to
the small chainring on a traditional 2x. Example: 50 x 0.68 = 34.
Shifting from 1:1 to the reduction ratio is like shifting from the large to the small chainring on a traditional 2x.
Large front chainring Virtual small front chainring (Classified) *
60 41
58 40
56 38
54 37
52 36
50 34
48 33
46 32
44 30
42 29
40 27
38 26
36 25
4. Principles of operation
14 4.1 The operation of the Classified Powershift hub

Classified Powershift hub
Large front chainring Virtual small front chainring (Classified) *
34 23
32 22
30 21
*: These values are rounded.
EN
4. Principles of operation
4.1 The operation of the Classified Powershift hub 15

Classified Powershift hub
EN
5. Configuration
5.1 Selecting and preparing the correct smart thru axle
First check if the Powershift hub can be installed on your bicycle. Please refer to Intended use on page 5.
Tools required:
•Dealer toolkit
•Classified frame tool
•3 mm socket wrench
•Cassette lock ring tool with internal diameter of > 19.5 mm
•External brake disc lock ring tool
•Torx T5 screwdriver (comes with the dropbar handlebar unit)
NOTE
If you do not have the required tools, it is advisable to obtain them from an oicial Classified dealer.
You must complete all the steps in this procedure, unless stated otherwise!
1. Measure the available distance (O.L.D.) for the hub.
•Is the measured distance 142 mm? Go to the next step.
•Is the measured distance 148 mm? Go to step 3.
2. Check how to install the torque support on the frame.
•The frame is designed for ITS (A) (Internal Torque Support). The thru axle and the brake side end cap are used as
torque support. Go to step 11.
•External torque support must be mounted on the brake side. ETS (B) (External Torque Support). Go to the next
step.
3. Check if the outside of the frame dropout on the brake side is conical.
•If it is conical, go to the next step.
•If it is not conical, go to step 5.
4. Install a conical ring (1) in the frame.
5. Configuration
16 5.1 Selecting and preparing the correct smart thru axle

Classified Powershift hub
5. Insert the Classified frame tool (2) completely into the frame dropout (3) on the brake side.
6. Select the thru axle based on the marking that matches the inside of the inner frame dropout. In this illustration, the
distance between A and B is for 142 mm.
•For 142: A, B, C, D
•For 148: C, D, E, F
7. Slide the Classified frame tool to the left until the surface of the frame dropout lines up with the selected thru axle
marking. In this illustration, you line up with 142 mm from B.
8. Turn the Classified frame tool 360°. If the Classified frame tool cannot keep turning, slide it to the left until it can
rotate freely. Now look at the Classified frame tool to check the new position of the frame dropout.
For example, C instead of B.
EN
5. Configuration
5.1 Selecting and preparing the correct smart thru axle 17

Classified Powershift hub
EN
9. Check if there is still space left between the Classified frame tool and the frame.
•If there is no space left between the Classified frame tool and the frame, go to step 11.
•If there is space left between the Classified frame tool and the frame, go to the next step.
10. Add spacers until the space has been filled.
11. Determine the correct pitch for the threaded end.
•Consult your bicycle manufacturer's website for the information.
•Check the marking on the previous thru axle. Example: M12 x P1.5.
•Compare the thread length of the previous thru axle to this thread end.
5. Configuration
18 5.1 Selecting and preparing the correct smart thru axle

Classified Powershift hub
12. Carefully try to screw the thru axle into the frame to check if you have chosen the right pitch for the thread end.
Unscrew the thru axle again.
13. Check how long the threaded end needs to be by placing the smart thru axle beside the original axle. Choose the
closest equivalent, preferably a bit longer.
14. Place the spacers on the thru axle. If a metal spacer (6) has to be added, ALWAYS slide it onto the thru axle between
2 plastic rings (5) (7).
NOTE
The edge on the side of the thru axle lever is not a spacer(!).
15. Install the thru axle in the frame.
16. Check that the marking is aligned with the inside of the dropout.
EN
5. Configuration
5.1 Selecting and preparing the correct smart thru axle 19

Classified Powershift hub
EN
•The position of the thru axle is OK. Go to the next step.
•The position of the thru axle is NOT OK. Go back to step 12 to place the correct number of spacers.
17. Install the smart thru axle (9), ensuring that the thru axle lever (8) points towards the handlebar unit.
If required, loosen the smart thru axle again and loosen the socket bolt (11) on the end of the smart thru axle. Now
the stud (10) can be removed from the axle and turned. Retighten the smart thru axle and check that the thru axle
lever points towards the handlebar unit. Repeat this until the thru axle lever points in the right direction.
NOTE
Only the threaded end may be removed from the axle. No other components of the thru axle should be
removed!
5. Configuration
20 5.1 Selecting and preparing the correct smart thru axle