I:SY E5 ZR F Quick guide

IMPORTANT
READ CAREFULLY BEFORE USE
KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE
Translation of the original operating instructions for
i:SY pedelecs with BOSCH Intuvia on-board computer
E5 ZR F | E5 ZR F Comfort | E5 ZR F LTD | E5 ZR RT | E5 ZR RT Comfort | E5 ZR RT LTD
N3.8 ZR F | N3.8 ZR F LTD | S8 K | XXL E5 ZR F Comfort | XXL E5 ZR RT Comfort
XXL N3.8 ZR F | XXL N3.8 ZR F LTD
G-01 … G-09, I-01 … I-04
M Y 2 3I0a - 5 2 _ 1 . 0 _ 2 9 . 0 8 . 2 0 2 3

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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 Toxic substances 20
2.2.2 Irritants and corrosive substances 20
2.3 Requirements for the rider 20
2.4 Vulnerable groups 20
2.5 Personal protective equipment 21
2.6 Safety guards 21
2.7 Safety markings and safety instructions 21
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
2.9 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 Fork 34
3.3.3 Suspension 35
3.3.3.1 Suspension seat post 35

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Contents
3.3.3.2 Tyre suspension 35
3.3.4 Wheel 36
3.3.4.1 Tyres 36
3.3.4.2 Tube-type tyre 36
3.3.4.3 Rim 38
3.3.4.4 Valve 38
3.3.4.5 Spoke 39
3.3.4.6 Spoke nipples 39
3.3.4.7 Hub 40
3.3.5 Saddle 41
3.3.5.1 Ladies’ saddle 42
3.3.5.2 Men’s saddle 42
3.3.6 Seat post 43
3.3.6.1 Patent seat post 43
3.3.6.2 Suspension seat post 43
3.3.7 Brake 45
3.3.7.1 Mechanical brake 45
3.3.7.2 Hydraulic brake 45
3.3.7.3 Disc brake 46
3.3.7.4 Back-pedal brake 47
3.3.8 Mechanical drive system 48
3.3.8.1 Chain drive layout 48
3.3.8.2 Parts of a belt drive 48
3.3.9 Electric drive system 49
3.3.9.1 Motor 49
3.3.9.2 Charger 49
3.3.9.3 Lighting 49
3.3.9.4 Rechargeable battery 49
3.3.9.5 On-board computer 51
3.3.9.6 Display 51
3.4 Description of controls and screens 52
3.4.1 Handlebars 52
3.4.2 BOSCH LED Remote on-board computer 53
3.4.2.1 Selected level of assistance indicator 54
3.4.2.2 ABS indicator (optional) 54
3.4.2.3 Battery level indicator (on-board computer) 54
3.4.2.4 System message 55
3.4.2.5 Software updates 56
3.4.2.6 Activity tracking 56
3.4.2.7 Lock function 57
3.4.3 BOSCH Intuvia 100 display 58
3.4.3.1 Settings 59
3.4.4 Handbrake 60
3.4.5 Rechargeable battery 61
3.4.5.1 Battery level indicator screen 61
3.5 Technical data 62
3.5.1 Pedelec 62
3.5.2 Emissions 62
3.5.3 Display mount BDS3YYY 62
3.5.4 LED Remote on-board computer 62
3.5.5 BOSCH Intuvia 100 display 62
3.5.6 BOSCH Performance Line CX motor 63
3.5.7 Rechargeable battery 63
3.5.7.1 BOSCH PowerTube 500 battery 63
3.5.7.2 BOSCH PowerTube 625 battery 63
3.5.7.3 BOSCH PowerTube 750 battery 63
3.5.7.4 BOSCH PowerPack 545 battery 64
3.5.7.5 BOSCH PowerPack 725 battery 64

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Contents
3.5.8 Bicycle lighting 64
3.5.9 Tyres 65
3.5.9.1 SCHWALBE puncture protection level 65
3.5.10 BY.SCHULZ G2 seat post 66
3.5.11 Torque 68
4 Transporting and storing
4.1 Weight and dimensions for transportation 79
4.2 Designated handles, lifting points 79
4.3 Transportation 80
4.3.1 Using the transport securing system 80
4.3.2 Transporting the pedelec 80
4.3.2.1 By car 80
4.3.2.2 By train 80
4.3.2.3 By local transport 81
4.3.2.4 By long-distance bus 81
4.3.2.5 On flights 81
4.3.3 Shipping a pedelec 81
4.3.4 Transporting the battery 81
4.3.5 Shipping the battery 81
4.4 Storing 82
4.4.1 Pedelec 82
4.4.2 On-board computer, display and charger 82
4.4.3 Rechargeable battery 82
4.4.4 Break in operation 83
4.4.4.1 Preparing for a break in operation 83
4.4.4.2 Carrying out a break in operation 83
5 Assembly
5.1 Unpacking 84
5.2 Required tools 84
5.3 Commissioning 85
5.3.1 Checking the battery 85
5.3.2 Preparing the battery 86
5.3.2.1 Retrofitting the PowerTube adapter 86
5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 87
5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 88
5.3.3 Adjusting the suspension system to body weight 89
5.3.3.1 Adjusting SR Suntour suspension elements 89
5.3.4 Preparing the wheel 90
5.3.5 Fitting the pedals 91
5.3.6 Checking the stem and handlebars 92
5.3.6.1 Checking the connections 92
5.3.6.2 Checking stem is firmly in position 92
5.3.6.3 Checking the bearing clearance 92
5.4 Selling the pedelec 92
6 Operation
6.1 Risks and hazards 93
6.2 Tips for a greater range 95
6.3 Error message 96
6.3.1 On-board computer 96
6.3.1.1 Critical errors 96
6.3.1.2 Less critical errors 96
6.3.2 Rechargeable battery 96

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Contents
6.4 Instruction and customer service 98
6.5 Adjusting the pedelec 98
6.5.1 Preparing 98
6.5.2 Determining the sitting position 99
6.5.3 Seat post 100
6.5.3.1 Adjusting the seat post to body weight 100
6.5.4 Saddle 100
6.5.4.1 Replacing the saddle 100
6.5.4.2 Determining the saddle shape 101
6.5.4.3 Determining the minimum saddle width 102
6.5.4.4 Selecting the saddle hardness 103
6.5.4.5 Adjusting the saddle hardness 103
6.5.4.6 Straightening the saddle 104
6.5.4.7 Adjusting the saddle height 104
6.5.4.8 Setting the saddle height with the remote control 105
6.5.4.9 Adjusting the saddle position 105
6.5.4.10 Adjusting the saddle tilt 106
6.5.4.11 Checking the saddle 106
6.5.5 Handlebars 107
6.5.5.1 Replacing the handlebars 107
6.5.5.2 Adjusting the handlebar width 107
6.5.5.3 Adjusting the hand position 107
6.5.5.4 Adjusting the handlebars 108
6.5.6 Stem 109
6.5.6.1 Replacing the stem 109
6.5.6.2 Adjusting the handlebar height with quick release 109
6.5.6.3 Checking the stem stability 109
6.5.6.4 Adjusting the quick release clamping force 109
6.5.6.5 Setting the quill stem 110
6.5.6.6 Adjusting the Ahead stem 110
6.5.6.7 Adjusting the angle-adjustable stem 110
6.5.6.8 Checking the stem 110
6.5.7 Handles 111
6.5.7.1 Replacing the handles 111
6.5.7.2 Adjusting ergonomic handles 111
6.5.7.3 Checking the handles 111
6.5.8 Tyres 112
6.5.8.1 Adjusting tyre pressure 112
6.5.9 Brake 113
6.5.9.1 Replacing brakes 113
6.5.9.2 Retracting the brake linings 113
6.5.9.3 Changing the handbrake position 113
6.5.9.4 Changing the handbrake inclination angle 114
6.5.9.5 Determining the grip distance 114
6.5.9.6 Setting the grip distance for a MAGURA handbrake disc brake 115
6.5.9.7 MAGURA handbrake pressure point 116
6.5.9.8 Setting the grip distance on a TEKTRO handbrake 117
6.5.10 Gear shift 118
6.5.10.1 Replacing the gear shift 118
6.5.10.2 Adjusting the SHIMANO shifter 118
6.5.11 Riding light 119
6.5.11.1 Replacing the headlight 119
6.5.11.2 Replacing the rear light and (spoke) reflector 119
6.5.11.3 Setting the riding light 119
6.5.11.4 Adjusting the headlight 120

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Contents
6.5.12 Adjusting the on-board computer 121
6.5.12.1 Creating a user account 121
6.5.12.2 Connecting the on-board computer to a smartphone 121
6.5.12.3 Updating the software 121
6.5.12.4 Activating activity tracking 121
6.5.12.5 Setting up the lock function (optional) 122
6.5.12.6 Inserting the battery 122
6.5.12.7 Inserting the display 123
6.5.12.8 Removing the on-board computer 123
6.5.12.9 Securing the on-board display (optional) 123
6.5.12.10 Adjusting the on-board computer 124
6.5.12.11 Adjust on-board computer 125
6.5.12.12 Selecting the language 125
6.5.12.13 Selecting units 125
6.5.12.14 Adjusting the clock 125
6.5.12.15 Setting the time format 125
6.5.12.16 Setting the shift recommendation 125
6.5.12.17 Adjusting the backlight 126
6.5.12.18 Setting the brightness 126
6.5.12.19 Resetting the settings 126
6.6 Accessories 127
6.6.1 Child seat 127
6.6.1.1 THULE, Yepp Nexxt Maxi 128
6.6.2 Trailer 128
6.6.2.1 Approval for trailer with SHIMANO hub 129
6.6.2.2 Approval for trailer with ENVIOLO hub 129
6.6.2.3 Approval for trailer with ROHLOFF hub 129
6.6.3 MonkeyLoad system 130
6.6.3.1 Attaching MonkeyLoad system components 130
6.6.3.2 Detaching MonkeyLoad system components 130
6.6.4 Front baskets 131
6.6.4.1 i:SY, KLICKfix Front Carrier 131
6.6.4.2 i:SY, MIK Front Carrier 131
6.6.4.3 i:SY, MAXI Front Carrier 132
6.6.4.4 i:SY, Lowrider 132
6.6.5 Panniers and cargo boxes 133
6.6.5.1 BASIL, Buddy Dog Basket by i:SY 133
6.6.5.2 Wire dome for the Buddy dog basket 133
6.6.5.3 i:SY, Front Shopping Basket 133
6.6.6 Mobile holder 134
6.6.6.1 Fastening the mobile 134
6.6.6.2 Releasing the mobile 134
6.6.6.3 Suspension fork coil spring 134
6.6.7 Saddle 134
6.6.8 Seat post 135
6.6.9 Bar ends 135
6.6.10 Protective covers 135
6.7 Personal protective equipment and accessories for road safety 136
6.8 Before each ride 136
6.9 Straightening the quickly adjustable stem 137
6.10 Using the pannier rack 137
6.11 Raising the kickstand 138
6.12 Using the saddle 138
6.12.1 Using the leather saddle 138
6.13 Using the pedals 138
6.14 Setting the saddle height with the remote control 139

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Contents
6.14.1 Lowering the saddle 139
6.14.2 Raising the saddle 139
6.15 Using the bell 139
6.16 Using the handlebars 139
6.16.1 Using multi-position handlebars 139
6.16.2 Using bar ends 140
6.16.3 Using leather handles 140
6.17 Using the battery 141
6.17.1 Inserting the battery 141
6.17.2 Removing the battery 141
6.17.3 Charging the battery 142
6.18 Using the electric drive system 143
6.18.1 Switching on the electric drive system 143
6.18.2 Switching off the electric drive system 143
6.19 Using the on-board computer 144
6.19.1 Using the diagnosis port 144
6.19.2 Charging the on-board computer battery 144
6.19.3 Using the riding light 145
6.19.4 Setting the brightness of indicators 145
6.19.5 Using the push assist system 145
6.19.6 Selecting the level of assistance 146
6.20 Using the brake 147
6.20.1 Using the handbrake 147
6.20.2 Using the back-pedal brake 147
6.20.3 Switching the SHIMANO Rapidfire derailleur gears 148
6.21 Gear shift 149
6.21.1 Using the belt gear shift 149
6.21.2 Using a SHIMANO hub gear 151
6.21.3 Using eShift 152
6.21.3.1 Using eShift with SHIMANO DI2 automatic hub gears 152
6.21.3.2 Using eShift with manual SHIMANO DI2 hub gears 152
6.21.3.3 Using eShift with SHIMANO DI2 automatic hub gears 152
6.21.4 Using an ENVIOLO gear shift gear 153
6.21.4.1 Switching gear manually 154
6.22 Parking 155
6.22.1 Screwing in the quickly adjustable stem 156
6.22.2 Folding up the pedal 156
6.22.3 Activating the lock function 157
7 Cleaning, maintenance and inspection
7.1 Before each ride 162
7.1.1 Checking the guards 162
7.1.2 Checking the frame 162
7.1.3 Checking the fork 162
7.1.4 Checking the rear frame damper 162
7.1.5 Checking the pannier rack 162
7.1.6 Checking the mudguards 162
7.1.7 Check wheel concentricity 162
7.1.8 Checking the quick releases 162
7.1.9 Checking the suspension seat post 163
7.1.10 Checking the bell 163
7.1.11 Checking the handles 163
7.1.12 Checking the USB cover 163
7.1.13 Checking the riding light 163
7.1.14 Checking the brake 163
7.2 After each ride 164
7.2.1 Cleaning the riding light and reflectors 164
7.2.2 Cleaning the suspension fork 164
7.2.3 Maintaining the suspension fork 164

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7.2.4 Cleaning the pedals 164
7.2.5 Cleaning the brake 164
7.2.6 Cleaning the suspension seat post 164
7.2.7 Cleaning the rear frame damper 164
7.3 Basic cleaning 165
7.3.1 Cleaning the on-board computer and control panel 165
7.3.2 Cleaning the battery 165
7.3.3 Cleaning the motor 165
7.3.4 Cleaning the frame, fork, pannier rack, guards and kickstand 166
7.3.5 Cleaning the stem 166
7.3.6 Cleaning the handlebars 166
7.3.7 Cleaning the handles 166
7.3.7.1 Cleaning leather handles 166
7.3.8 Cleaning the seat post 166
7.3.9 Cleaning the saddle 167
7.3.9.1 Cleaning the leather saddle 167
7.3.10 Cleaning the tyres 167
7.3.11 Cleaning the spokes and spoke nipples 167
7.3.12 Cleaning the hub 167
7.3.13 Cleaning the switching elements 167
7.3.14 Cleaning the SRAM AXS rear derailleur 167
7.3.14.1 Cleaning the shifter 168
7.3.15 Cleaning the cassette, chain wheels and front derailleur 168
7.3.16 Cleaning the brake 168
7.3.16.1 Cleaning the handbrake 168
7.3.17 Cleaning the brake disc 168
7.3.18 Cleaning the belt 168
7.3.19 Cleaning the chain 169
7.3.19.1 Cleaning the chain, including all-round chain guard 169
7.4 Maintenance 170
7.4.1 Maintain frame 170
7.4.2 Maintain fork 170
7.4.3 Maintain pannier rack 171
7.4.4 Maintain mudguard 171
7.4.5 Servicing the kickstand 171
7.4.6 Maintaining the stem 171
7.4.7 Maintaining the handlebars 171
7.4.8 Maintaining the handles 172
7.4.8.1 Maintaining rubber handles 172
7.4.8.2 Maintaining the leather handles 172
7.4.9 Maintaining the seat post 172
7.4.9.1 Maintaining the suspension seat post 172
7.4.9.2 Maintaining the carbon seat post 172
7.4.10 Maintaining the rims 172
7.4.11 Maintaining the leather saddle 172
7.4.12 Maintaining the hub 173
7.4.13 Maintaining the spoke nipples 173
7.4.14 Maintaining the gear shift 173
7.4.14.1 Maintaining the rear derailleur articulated shafts and jockey wheel 173
7.4.14.2 Maintaining the shifter 173
7.4.15 Maintaining the pedals 173
7.4.16 Maintaining the chain 174
7.4.16.1 Maintaining the chain and all-round chain guard 174
7.4.17 Maintaining the battery 174
7.4.18 Maintaining the brake 175
7.4.18.1 Maintaining the handbrake 175
7.4.19 Lubricating the Eightpins seat post tube 175

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Contents
7.5 Inspection 176
7.5.1 Checking the wheel 176
7.5.1.1 Checking tyre pressure 176
7.5.1.2 Checking the tyres 178
7.5.1.3 Checking the rims 179
7.5.1.4 Checking the nipple holes 179
7.5.1.5 Checking the nipple well 179
7.5.1.6 Checking the rim hooks 179
7.5.1.7 Checking the spokes 179
7.5.2 Checking the brake system 180
7.5.2.1 Checking the handbrake 180
7.5.2.2 Checking the hydraulic brake system 180
7.5.2.3 Checking the Bowden cables 180
7.5.2.4 Checking the disc brake 181
7.5.2.5 Checking the back-pedal brake 182
7.5.3 Checking the chain 183
7.5.3.1 Checking the chain tension 183
7.5.3.2 Checking the belt for wear 183
7.5.4 Checking the belt 185
7.5.4.1 Checking the belt for wear 185
7.5.4.2 Checking the belt sprockets for wear 185
7.5.4.3 Checking the belt tension 185
7.5.5 Checking the riding light 188
7.5.6 Checking the stem 189
7.5.7 Checking the handlebars 189
7.5.8 Checking the saddle 189
7.5.9 Checking the seat post 189
7.5.10 Checking the pedal 189
7.5.11 Checking the gear shift 190
7.5.11.1 Checking the electric gear shift 190
7.5.11.2 Checking the mechanical gear shift 190
7.5.11.3 Checking derailleur gears 190
7.5.11.4 Checking the hub gear 190
7.5.11.5 Adjusting the ROHLOFF hub 191
7.5.11.6 Adjusting the cable-operated gear shift, dual-cable 191
7.5.11.7 Adjusting the dual-cable, Bowden-cable-operated twist grip shifter 191
7.5.11.8 Checking kickstand stability 192
8 Inspection and maintenance
8.1 Initial inspection 193
8.2 Major inspection 193
8.3 Component-specific maintenance 193
8.4 Carry out initial inspection 196
8.5 Perform major inspection 197
8.5.1 Inspect frame 204
8.5.1.1 Inspecting the carbon frame 204
8.5.2 Inspecting the pannier rack 204
8.5.3 Inspecting and maintaining the rear frame damper 204
8.5.4 Inspecting the gear hub 205
8.5.4.1 Adjusting the hub with cone bearing 205
8.5.5 Inspecting the stem 205
8.5.6 Inspect and grease steering headset 205
8.5.7 Inspecting the axle with quick release 206
8.5.8 Inspecting the fork 207
8.5.8.1 Inspecting the carbon suspension fork 207
8.5.8.2 Inspecting the suspension fork 207
8.5.9 Inspecting the seat post 208
8.5.9.1 Inspecting the carbon seat post 208
8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post 208
8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post 209

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Contents
9 Troubleshooting, fault clearance and repair
9.1 Preventing pain 210
9.1.1 Sitting discomfort 211
9.1.2 Pain in hips 211
9.1.3 Backache 211
9.1.4 Pain in shoulders and nape of neck 212
9.1.5 Numb or aching hands 212
9.1.6 Pain in upper thigh 212
9.1.7 Knee pain 213
9.1.8 Pain in the foot 213
9.2 Troubleshooting and fault clearance 214
9.2.1 Drive system or on-board computer does not start up 214
9.2.2 Errors in assistance function 215
9.2.3 Battery errors 216
9.2.4 Display screen errors 217
9.2.5 Lighting does not work 217
9.2.6 Correcting disc brake faults 218
9.2.7 Problems with back-pedal brake 219
9.2.8 Problems with hub gear 220
9.2.9 Correcting freewheel faults 222
9.2.10 Correcting lighting faults 223
9.2.11 Correcting faults in tyres 223
9.2.12 Correcting control seat post faults 223
9.2.13 Correcting other faults and errors 224
9.3 Repairs at the specialist dealer 225
9.3.1 Original parts and lubricants 225
9.3.2 Repairing the frame 225
9.3.2.1 Removing paint damage on frame 225
9.3.2.2 Removing damage from impact on the carbon frame 225
9.3.3 Repairing the suspension fork 225
9.3.3.1 Removing paint damage on the fork 225
9.3.3.2 Removing damage from impact on the carbon frame 225
9.3.3.3 Repairing the seat post 225
9.3.3.4 Repairing damage from impact on the carbon seat post 225
9.3.4 Replacing the riding light 226
9.3.5 Adjusting the headlight 226
9.3.6 Checking suspension fork-tyre clearance 226
9.3.7 Replacing pedelec components if lock function is installed 227
9.3.7.1 Replacing a smartphone 227
9.3.7.2 Replacing the on-board computer 227
9.3.7.3 Activating the lock function after motor replacement 227
10 Recycling and disposal
10.1 Guidelines on removal of waste 228
11 Documents
11.1 Assembly report 230
11.2 Inspection and maintenance log 232
11.3 Parts list 236
11.3.1 E5 ZR F, POP ART E5 ZR F 236
11.3.2 E5 ZR F Comfort 238
11.3.3 E5 ZR RT, POP ART E5 ZR RT 240
11.3.4 E5 ZR RT Comfort 242
11.3.5 N3.8 ZR 244