Felt BruHaul User manual

BrüHaul
OWNER’S MANUAL

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BRÜHAUL
Congratulations! You are the proud owner of a Felt BrüHaul
cargo e-bike.
At Felt, our mission is simple: Build the world’s best bikes. Period.
We are passionate about that and strive to achieve it in each and
every single bike we make. The new BrüHaul is an example of
that passion.
Please carefully read through this manual. It will help you
understand and get the most use and enjoyment out of
what we believe is the best cargo e-bike you can ride.
For further information, visit:
FELTELECTRIC.COM
INTRODUCTION CONTENTS
BrüHaul Design .....................................................................................2-3
The Bosch e-Drive System ......................................................................4-5
Loading and Riding the BrüHaul ...........................................................6-8
Cargo .................................................................................................. 9-10
Passengers .........................................................................................11-15
Locking and Transport ............................................................................ 15
BrüHaul Maintenance ............................................................................. 16
Cycling Society Notes ............................................................................. 17
BrüHaul Accessories ............................................................................... 18
Accessory Instructions........................................................................19-22
Contact................................................................................................... 23

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BRÜHAUL
Cargo bikes are like the 18-wheelers of the bike world, and some of them handle like
it. We designed the BrüHaul to be the stiffest and lightest cargo e-bike available. To
do so, we made it the stiffest and lightest e-Cargo bike available. That makes BrüHaul
more efficient and allows it to handle more like a standard sized bicycle rather than a
long tail bicycle. The BruHaul is stable, predictable and fun to ride.
The BruHaul is flexible in the number of ways it can be configured for carrying loads.
From kids and adults to groceries and ice cold brews, the BrüHaul can be configured
to haul just about anything.
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1. Frame Design
The BrüHaul is made from lightweight T6061 aluminum with shaped tubes that
enhance rigidity and are double butted for strength. The stiffness of the frame,
enhanced by the tapered headtube, allows the BrüHaul to have agile and
consistent handling – empty or fully loaded. The BrüHaul was designed, from its
inception, to integrate Bosch’s world-leading eDrive system while increasing the
stiffness at the bottom bracket.
2. Load Deck and Integrated Pannier Rack
The integrated load deck and pannier rack make it a breeze to equip your
BrüHaul to carry all your precious cargo. There is a full line of accessories
available for your BrüHaul. See the back of this manual or go to www.
FeltBicycles.com for more information.
3. Brakes
The BrüHaul is designed to be used at full capacity. Oversized Shimano brakes
that use a 180mm rotor in the front and 160mm rotor in the rear provide serious
stopping power in all types of weather.
4. Full Front and Rear Fenders
The BrüHaul comes with both front and rear fenders to ensure that you can
continue to ride in rainy weather conditions.
5. Weight
50 pounds (23 kg) – including the Bosch eDrive system and battery. Less
weight means less energy is needed to move, so you’ll go farther on a charge.
In addition, the BruHaul’s light weight means better acceleration, handling and
braking response than other cargo bikes.
6. 24” Wheels
We chose 24” wheels because they deliver a stabilizing low center of gravity,
effort-reducing torque transfer from the motor and ride-smoothing roll-over
characteristics.
7. Front and Rear Lights – Standard
The BrüHaul lights the road and makes you visible so you and your cargo
get to your destination safely.
BRÜHAUL DESIGN

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THE BOSCH E-DRIVE SYSTEM
Overview
The multiple award-winning Bosch e-Drive System in the BrüHaul is, at 350
watts, the highest output Bosch system currently available in North America.
The system monitors rider output, cadence and speed providing 1,000
measurements each second. This delivers a seamless power boost at the rider’s
chosen level an instant, seamless power cut-off when pedaling stops (critical for
negotiating tight turns with heavy loads and loose surfaces).
Because it is a mid-motor system, the BrüHaul gives riders a full 10-speed gear
range to help with the heaviest loads, the steepest hills and to get the most
efficient performance from the electric motor.
Intuvia Control Center
The control unit consists of a switch panel located within thumb’s reach and
the display unit mounted near the center of the handlebars. The assist level is
chosen by pressing the up or down button on the switch panel. In addition to
assist level, the display provides bike computer functions including: Range, Trip
Distance and Trip Time. There is also a USB port for charging your phone.
The system provides ve assist modes:
“Off” - 0% assistance
“Eco” - 50% assist: Your power + 50% more.
“Tour” - 120% assist.
“Sport” - 190% assist.
“Turbo” - 275% assist.
THE BOSCH E-DRIVE SYSTEM
Range
The BrüHaul is equipped with Bosch’s 400 watt hour (Wh) PowerPack 400
battery that is downtube or rack mounted. Depending on variables like gear
selection, tire pressure, total weight, road surface, temperature and assist
level, the PowerPack 400 can provide a maximum range of up to 75 miles in
Eco mode and over 45 miles across a general mix of modes.
Because it is heavier than the rest of the bikes in the Felt eBike lineup
and because you’ll probably be employing its increased cargo capacity,
your range will likely be less with the BrüHaul.
Battery Care
The PowerPack 400 employs a standard, 110 V plug-in charger (included).
50% charge is reached in just 1.5 hours and a full charge takes less than 3.5
hours. The battery will operate at full strength for 500 cycles (about two years)
after which it will retain about 60% of its original capacity. In all, the battery
will be serviceable for between 15,000 and 30,000 miles.
After the cost of purchase, the Felt eBikes cost about ½ cent per mile to
charge and maintain.

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LOADING AND RIDING
THE BRÜHAUL
Pre-Ride Checks
Your BrüHaul needs both its mechanical and electric systems fully functional to
give you the best and longest ride. Here are two quick check procedures to do
before every ride.
Mechanical
Make sure to check your bike before every ride. Go through the following
check-list for safety and function.
A is for Air (in the tires) - check to make sure there is plenty in there!
B is for Brakes – brake pads wear – especially if you frequently ride the
BrüHaul well loaded.
• Pull the brake levers – if you can squeeze them to within 1” of the bar grips,
it is time to have them serviced
• When moving, listen for a grinding sound that indicates worn-out brake
pads
• Visually inspect the rotors for wear of the stainless steel braking surface
• Visually inspect the brake cables for signs of wear
C is for Chain and Cables
The chain and cables on the BrüHaul are long and require weekly visual
inspection and lubrication.
• At the end of each day wipe down the chain and apply lubricant as
necessary
• The cable that runs to the rear derailleur should be inspected daily and
lubed weekly if you are in rainy or damp conditions. (As with any multi-
cogged drivetrain, a snapped derailleur cable will default the bike into its
highest gear making for a potentially difficult ride home).
Make sure the Quick Release levers at both wheels are tightly in the “closed”
position. Up against the fork in the front and bisecting the angle of the triangle
at the rear. In those positions they are most protected from stray hits.
Listen for any rattling that is a warning of loose parts – like fenders or racks or
seats you may have attached. Fix those issues before you ride.
Bosch e-Drive System Check
The Bosch e-Drive system is maintenance free so, check to make sure the battery
has enough charge for the intended length of your ride via the Intuvia Control’s
“Range” function.
Unloaded Riding
The BrüHaul wheelbase is longer and the head tube has more slack than your
average bike. Because it weighs more, the BrüHaul takes longer to get going
and longer to stop too. So, as you’re riding the BrüHaul, think a little farther
down the road than you would on a smaller, lighter bike.
Set the saddle height of the BrüHaul so that your feet can easily reach the
ground and provide a solid base. Ride far enough from the side of the road or
lane so that you have room to maneuver around road hazards like potholes
and are out of that zone of debris lining the sides of many roads.
LOADING AND RIDING
THE BRÜHAUL

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Loaded Riding
BrüHaul comes standard ready to haul people and/or cargo.
LOADING AND RIDING
THE BRÜHAUL
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Stock BrüHaul Conguration
1 & 2 Rack with Load Deck
The integrated rack and load deck (1) accommodates people, child seats,
pannier bags. There are four bolt holes on either side of the load deck (2) for
attaching M5-sized eyebolts for light duty tie-down attachments.
3 Foot Loops
The foot loops (3) provide a place to hook longer bungee cords to secure cargo
and they also accept our bamboo foot plate kit for passengers (see “Carrying
Passengers”).
4 & 5 Additional Attachment Points
There is also an M6-sized, threaded hole through the top tube (4) and an M5-
sized one on either side of the fork (5) which may be used to help secure very
long loads.
CARGO
WARNING
Total Maximum Weight Restriction (Bike + Payload) = 400 pounds
(unloaded bike weight = 50 pounds)
Total Maximum Load Deck Capacity = 200 pounds
4 pannier bags and a youth seat.2 pannier bags and a child seat.
Sample Cargo Congurations
Loading your bike
The integrated rack on the BrüHaul accepts Genuine Felt and other pannier
bags as well as seats for infants and children. The rack system allows for
tremendous flexibility in set-up; allowing you freedom in how you configure the
bike to haul your cargo. To preserve BrüHaul’s handling and stability, follow
these general guidelines:
1. Place heavier objects ahead of lighter ones. Concentrating mass towards
the center of the bike will minimize the impact a load has on BrüHaul
handling.
2. Place objects as low on the bike as you can. Doing so will make it easier
to stop and start and increase the bike’s stability as you ride – especially at
low speeds.
3. Load side-to-side and front-to-back. Attaching two, heavily loaded pannier
bags to one side of the BrüHaul may make it tip over. Put bags in the
forward position first, then in the rear positions.

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CARGO
When loading odd-sized cargo
1. Make sure there is clearance for you to get onto and safely operate the bike.
2. Get the heaviest part of the load as low as possible to maximize stability.
3. Tie long things together to reduce their vibration as you pick up speed.
Getting Under Way with Cargo
1. Make sure your cargo is well-secured and as low on the bike as possible.
Use pannier bags and milk crates to carry all but oversized cargo.
2. If your cargo is extra-long, make sure you flag it so that motor vehicles,
other cyclists and pedestrians see and avoid it.
3. Smoothness in take-off, turning and braking is critical to getting cargo loads
safely to journey’s end.
4. Make sure that the chain is on or close to the largest cog before you load
the bike. The shifter on the right controls that.
5. Select any of the three upper boost modes on the Bosch Intuvia control
panel “Tour,” “Sport,” or “Turbo” depending on the size of the load you are
hauling. You want a smooth start without spinning the rear wheel so don’t
select too great a boost level
6. Practice some low speed maneuvers before heading out into traffic to make
sure everything is secure and to understand how the load will affect the
bike’s handling.
7. Pre-plan your route – no dodging traffic, racing red lights or bunny-hopping
speed bumps here. Pre-plan a route with enough width for you to maneuver
oversized cargo on the BrüHaul.
Carrying Passengers
General Passenger Rules
1. Passengers should always wear helmets.
2. Use our Bamboo Foot Plates or clamp-on foot pegs for carriers similar to
the Yepp Jr for passengers not in child carriers.
3. Passengers will affect BrüHaul steering and stopping distances more than
any other cargo. Ask them to stay seated and keep their hands inside the
cockpit for the entire ride.
4. Be a good captain. Let them know when it’s about to be bumpy or any
obstacles are in the path of the bike.
5. Practice on-boarding, taking off and slow-speed maneuvers with your crew
Loading/unloading and starting/stopping are the least stable of times for
any cargo bike, make sure you and your crew are practiced at it before you
are in busy riding conditions. There is also a power kickstand accessory
available that lifts away at the touch of a button. (See the Accessories
section of this manual)
6. Know your local laws about carrying passengers on bikes. Check
the League of American Bicyclists’ Bike Laws Page: BikeLeague.org/
StateBikeLaws
PASSENGERS

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Passenger Congurations
BrüHaul can carry passengers in several configurations. Don’t forget that the
Total Maximum Weight Restriction (Bike + Payload) is 400 pounds. For
most riders, that means the maximum cargo weight (passengers + stuff) is
somewhere under 200 pounds.
Figure 1. Adolescent and Adult Seating Conguration
Showing Bamboo Footplate and Skirt Guard Kits
Figure 2. Showing Child and Youth Conguration
The Yepp Maxi (9 mos to 49 lbs) behind the Yepp Junior (5 yrs to 77 lbs)
Note: Required Footplate and Skirt Guard not shown; Yepp child seats fit the
BrüHaul directly, there is no need for an adapter.
Figure 3. Showing Two Child Conguration
Two Yepp Maxi Child Seats (up to 49 lbs each)
Note: Footplate Kit and Skirt Guard not required
PASSENGERSPASSENGERS
Figure 4. Showing Two Youth Conguration
Yepp Junior Seats (up to 77 lbs each)
Note: Footplate Kit and Skirt Guard not shown but required

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PASSENGERSPASSENGERS
Starting and Stopping with Passengers
Again, passengers are the heaviest thing you’ll carry, but the BrüHaul with the
Bosch eDrive system makes it easy.
Smooth take-offs are key and here’s our suggested method:
1. Let your passengers know what to expect. Let them know you will warn them
of bumps, stops and turns.
2. Smoothness in take-off, turning and braking is the key to safe, enjoyable
rides with passengers.
3. Make sure that the chain is on or close to the largest cog. The shifter on the
right controls that.
4. Select any of the three upper boost modes on the Bosch Intuvia control
panel “Tour,” “Sport,” or “Turbo” depending on the size of the load you are
hauling; You want a smooth start without spinning the rear wheel so don’t
select too great a boost level.
5. Tell your passenger’s when to pick up their feet and, as they do, begin
pedaling.
6. Practice some low speed maneuvers with your passengers so you both get a
feel for the bike’s handling.
Using the Bosch eDrive System to Maximum Effect
Your Bosch e-Drive system can deliver maximum torque as soon as you begin
pedaling. We chose 24” wheels for BrüHaul to give the ideal combination
of stability, roll-over capabilities and ability to apply torque from the e-Drive
system to the road.
If you are carrying a heavy load, on a dry surface, click the Intuvia control up
to “Turbo Mode” to get maximum assistance as you take off. You may want
to back it down to “Sport Mode” if you are taking off from a loosely packed
or wet surface.
Foul Weather Riding
Take advantage of the BrüHaul’s standard full fenders and lighting. When riding
in wet conditions, remember:
• Brake early and easily. It will take longer to stop and loose road surfaces –
as along the side of an intersection – can give-way under your tires causing
skidding and loss of balance.
• Turn on your lights. They come standard on BrüHaul and many states
require bikes to have lights on if motor vehicles must have theirs on (such
as when it is raining).
LOCKING AND TRANSPORT
Bike Racks
Lock your BrüHaul with two (2) U-Locks. Use one of the locks to secure the front
wheel and frame to a secure object. Use the second U-Lock to secure the rear
wheel to the frame.
Public Transit
Ask your dealer, regional transit authority or local advocacy group about bike
transportation on area public transportation.

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CYCLING SOCIETY NOTESBRÜHAUL MAINTENANCE
BrüHaul Systems Maintenance
With any bike, maintenance is important. If you ride it regularly, your BrüHaul
will need a derailleur adjustment soon after your purchase as the new shifter
cable will have stretched. At that time, you should also have the brake fluid
checked and the brake pads will have bedded in.
Beyond that, the ABC Quick Drop test should be performed before every ride
and, each week, you should check the tightness of the stem bolts, your water-
bottle cages, seat post clamp and any other accessories you have mounted to
the bike.
Bosch eDrive Maintenance
Please refer to the Bosch e-Drive manual that came with your bike
As a cargo bike rider you move into the category of dedicated bicyclists who are
in it for local transportation. As a transportational cyclist, you are more affected
by urban and sub-urban infrastructure and road sharing issues than many sport
cyclists who ride on less trafficked roads, multi-use paths or mountain trails.
There are three organizations you should consider connecting with as they can
provide you with significant resources to understand, safely and enjoyably ride
on your local roads. They are:
The League of American Bicyclists
At the forefront of teaching cyclists to survive and thrive on America’s public
roadways is the LAB. They offer online safe cycling courses and local instructors
to provide certifications. The League also has a multitude of resources to teach
you what you need to safely navigate roads you will be sharing with motor
vehicles. http://BikeLeague.org
People for Bikes
People for Bikes is the national bicycle advocacy group. They compile bicycling
statistics, lobby Washington to direct highway funds to improve bicycling
infrastructure, and provide grants for local cycling infrastructure development.
http://PeopleForBikes.org
Get involved with your local cycling advocates
More and more, there are bicycling advocacy groups in towns and cities across
the country. They work for things like placement of bike lanes, run local bike-to-
work day activities and often provide local League of American Bicyclists testing
and certification. Ask your local bike shop how to reach them.

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ACCESSORY INSTRUCTIONSBRÜHAUL ACCESSORIES
These accessories have been developed specifically for your BrüHaul. Get them
from your authorized Felt dealer.
Bamboo Footplate Kit (Part #: 9000141)
Includes bamboo footplates and attachment hardware for passengers too large
to fit into the Yepp Maxi seat (over 49lb/22kg).
Skirt Guard Kit (Part #: 9000142)
A light plastic shield that prevents feet, shoelaces, skirts, etc., from becoming
tangled in the rear wheel spokes and causing injury. For passengers too large
to fit into the Yepp Maxi seat (over 49lb/22kg). Note: the Skirt Guard is included
with the Yepp Youth seat.
Seat Pad Kit for BrüHaul Integrated Cargo Rack (Part #: 9000143)
Two pads which bolt to the integrated rack so passengers riding directly on the
rack are more comfortable.
Stoker Bar Kit (Part #: 9000144)
Handlebar and stem for front passenger. Attaches to seat post.
Yepp Child Seats
For children aged 9 months and up. Award winning child seats designed in the
Netherlands and available at retailers throughout North America. The BrüHaul’s
integrated rack accepts the Yepp seats directly, without need for an adapter.
More information available at www.yepp.nl.
Rolling Jackass Remote Kickstand
This remote-released center stand with an internally-routed cable control which
allows you to load your BrüHaul, then step over the top tube, pull its handlebar-
mounted lever and ride away. It is perfect for smooth take-offs with large,
unruly loads be they animate or inanimate. Custom-made for the BrüHaul.
More information at www.RollingJackass.com. You can have your authorized
Felt dealer order and install a Rolling Jackass Center Stand for you – or do it
yourself.
Additional Accessories for your Felt BrüHaul
A full line of parts and accessories for your Felt eBike, including genuine Felt
pannier bags, bar mounted cup holders and Felt apparel can be found at
WWW.FELTBICYCLES.COM
Bamboo Footplate Kit Installation
Included Parts
2 Bamboo Footplates
4 Black Plastic Frame Clips
8 Allen Head Machine Footplate Bolts
4 Footplate Nuts
22 FootplateWashers
Required Tools
Metric bicycle multi-tool or Allen wrench set
Small metric wrench to fit the nuts used to secure the Footplate thru-bolts to the
frame’s foot loop
Micro Torque wrench (optional)
Installation Steps
1. Insert black Footplate clips (1) onto the loops on the left side of the frame
as per the illustration. Make sure that the screw holes are on the outside
of the frame hoops so that they line up with the holes in the Bamboo
Footplate.

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2. Place the Footplate on the hoop and line up with holes of the clips and the
chainstays.
3. Place washers onto each of two bolts and attach them to the frame through
the holes in the Footplate that line up with the rear chainstay hole. Do not
fully tighten.
4. If you will be adding the Skirt Guard accessory, do not attach the front
screw until you are installing the Skirt Guard.
5. Place a washer (not shown) onto each of two bolts and put the bolts
through the holes on the outer edge of the Footplate and through the clips.
6. Place a second washer (not shown) and a nut onto the bottom of the screws
underneath the clip.
7. Tighten all Footplate bolts to 5Nm
8. Repeat the procedure for the other side of the bike.
9. Check weekly to ensure that the Footplate bolts are tight.
10. Have Fun!
ACCESSORY INSTRUCTIONSACCESSORY INSTRUCTIONS
Skirt Guard Kit Installation
Included Parts
2 Plastic Skirt Guards
4 M6 Bolts
2 M5 Bolts
2 Skirt Guard Mounting Tabs
Required Tools
Power Drill with ¼” bit and a scrap wood block
Metric bicycle multi-tool or Allen wrench set
Permanent Ink Marker
Micro Torque wrench (optional)
Installation Steps
1. If the Bamboo Footplate Kit (Part # 9000141) has been installed, remove
the inside front mounting bolt (at the chainstay).
2. Place a washer and a Skirt Guard Mounting Tab onto a bolt and screw
the bolt through the front, inboard hole and into the hole in the chainstay.
Make sure the Mounting Tab is oriented so that its vertical surface
faces away from the bike (1, below).

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3. Tighten the Footplate bolt to 5Nm making sure to preserve the proper
orientation of the Skirt Guard Mounting Tab
4. Attach the Skirt Guard at Point 2 with one of the M6-sized bolts.
5. Pull the Skirt Guard taut at Point 1 and mark where it overlaps the bolt hole
on the Load Deck upright using your marker pen.
6. Place the scrap wood block behind the mark and, using the ¼” bit, drill a
hole through the Skirt Guard at the mark.
7. Using an M6-sized bolt, attach the Skirt Guard to the Load Deck upright.
8. Pull the Skirt Guard taught at Point 3 and mark where it overlaps the hole
on the vertical face of the Mounting Tab.
9. Place the scrap wood block behind the mark and, using the ¼” bit, drill a
hole through the Skirt Guard at the mark.
10. Using the M5-sized bolt, attach the front of the Skirt Guard to the Mounting
Tab.
11. Torque all three Skirt Guard bolts to 3Nm.
12. Repeat the procedure for the other side of the bike.
13. Check weekly to ensure that the Skirt Guard bolts are tight.
ACCESSORY INSTRUCTIONS CONTACT INFORMATION
Felt Racing, LLC
12 Chrysler
Irvine, CA 92618
USA
WWW.FELTELECTRIC.COM
Felt GmbH
Industriestr. 39
26188 Edewecht
Germany