Kettler Quadriga Comp Belt Wiring diagram

TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KB110-ZXKD, KB110-ZXKT, KB110-ZXKW, KB115-ZXKD, KB115-ZXKT, KB115-ZXKW, KB128-ZXKD,
KB128-ZXKW, KB129-ZXKD, KB129-ZXKW, KB131-ZXKD, KB132-ZXFD, KB132-ZXFW, KB138-ZXKD
MY22K01 - 32_1.0_26.08.2021
Quadrig DUO CX E-TR, Quadrig DUO CX12, Quadrig DUO CX12 FS, Quadrig DUO CX12 SUV FS, Quad-
rig Pro Belt, Quadrig Pro CX12, Quadrig Town&Country Pro
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Translation of original operating instructions for
KETTLER Pedelecs with BOSCH Kiox
on-board computer
Quadriga
Comp Belt, Comp CX 11, Cross Pro CX 11, Duo CX10, Duo CX12, Duo CX12 FS, Duo CX12 FS SUV, Duo CX5,
Duo E-TR Belt, Pro Belt, PRO Belt, Pro CX 11, SUV Urban, Town & Country C1, Town & Country C2
Scarpia
FS 1.0 LTD Gold, FS 1.0 LTD Silver, FS 2.0, FS 3.0
KB060-xxKD, KB061-xxFD, KB063-xxKD, KB064-xxFD, KB089-xxKD…xxKW, KB091-xxKD, KB103-xxKD,
KB128-xxKD…xxKW, KB129-xxFD…xxFW, KB131-xxKD, KB132-xxFD…xxFW, KB138-xxKD…xxKD,
KB145-xxKD...xxKW, KB146-xxFD…xxFW, KS127-xxKD, KS128-xxKD, KS129-xxKD, KS130-xxKD
MY22K01 - 32_1.0_20:04:2021

MY22K01 - 32_1.0_26.08.2021 1
Contents
Contents
1 About these operating instructions
1.1 Manufacturer 12
1.2 Laws, standards and directives 12
1.3 Language 12
1.4 For your information 12
1.4.1 Warnings 12
1.4.2 Markups 12
1.5 Type number and model 13
1.6 Frame number 13
1.7 Identifying the operating instructions 13
1.8 Aim of the operating instructions 14
2 Safety
2.1 Residual risks 15
2.1.1 Risk of fire and explosion 15
2.1.1.1 Rechargeable battery 15
2.1.1.2 Overheated charger 15
2.1.1.3 Hot components 15
2.1.2 Electric shock 16
2.1.2.1 Damage 16
2.1.2.2 Water penetration 16
2.1.2.3 Condensation 16
2.1.3 Risk of a crash 16
2.1.3.1 Incorrect quick release setting 16
2.1.3.2 Incorrect tightening torque 16
2.1.3.3 Incorrect component 16
2.1.4 Risk of amputation 16
2.1.5 Key breaking off 16
2.1.6 Malfunctions due to Bluetooth® 17
2.2 Toxic substances 18
2.2.1 Brake fluid 18
2.2.2 Suspension oil 18
2.2.3 Lubrication oil 18
2.2.4 Defective battery 18
2.3 Requirements for riders 18
2.4 Vulnerable groups 18
2.5 Personal protective equipment 18
2.6 Safety guards 18
2.7 Safety markings and safety instructions 19
2.8 What to do in an emergency 19
2.8.1 Dangerous situation in road traffic 19
2.8.2 Leaked brake fluid 19
2.8.3 Battery vapours emitted 20
2.8.4 Battery fire 20
2.8.5 Oil and lubricant leaks from the rear frame damper 20
2.8.6 Oil and lubricant leaks from the fork 20
3 Description
3.1 Proper use 21
3.1.1 Improper use 22
3.1.2 Permitted total weight (PTW) 23
3.1.3 Environmental requirements 24
3.2 Nameplate 26
3.3 Components 27
3.3.1 Overview 27

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Contents
3.3.2 Chassis 28
3.3.2.1 Frame 28
3.3.2.2 Steering system 28
3.3.2.3 Steering headset 28
3.3.2.4 Stem 28
3.3.2.5 Handlebars 29
3.3.2.6 Fork 29
3.3.3 Wheel 30
3.3.3.1 Tyres 30
3.3.3.2 Rim 30
3.3.3.3 Valve 30
3.3.3.4 Spoke 31
3.3.3.5 Spoke nipples 31
3.3.3.6 Hub 31
3.3.4 Braking system 32
3.3.4.1 Mechanical brake 32
3.3.4.2 Hydraulic brake 32
3.3.4.3 Disc brake 33
3.3.4.4 Rim brake 34
3.3.4.5 Back-pedal brake 35
3.3.5 Seat post 36
3.3.5.1 Patent seat post 36
3.3.5.2 Suspension seat post 36
3.3.6 Mechanical drive system 37
3.3.6.1 Chain drive layout 37
3.3.6.2 Belt drive layout 37
3.3.7 Electric drive system 38
3.3.7.1 Motor 38
3.3.7.2 Rechargeable battery 38
3.3.7.3 Charger 39
3.3.8 Lighting 39
3.3.9 Suspension 40
3.3.9.1 Rigid fork 40
3.3.9.2 Suspension fork 40
3.3.9.3 Rear frame damper 44
3.3.9.4 RockShox rear frame damper 47
3.3.10 Electric drive system 48
3.3.10.1 Motor 48
3.3.10.2 Rechargeable battery 48
3.3.10.3 Frame battery 49
3.3.10.4 Pannier rack battery 49
3.3.10.5 Integrated battery 50
3.3.10.6 Charger 50
3.3.11 Lighting 50
3.3.12 On-board computer 51
3.3.12.1 USB port 51
3.3.13 Control panel 51
3.4 Description of controls and screens 52
3.4.1 Handlebars 52
3.4.2 On-board computer 53
3.4.2.1 START SCREEN 53
3.4.2.2 Status bar 55
3.4.2.3 STATUS SCREEN 55
3.4.2.4 QUICK MENU 55
3.4.2.5 SETTINGS 55
3.4.2.6 Additional journey information for eShift Shimano DI2 and Rohloff 57
3.4.2.7 Additional eShift system setting 57
3.4.2.8 Creating a user account 57
3.4.2.9 Software updates 57

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Contents
3.4.2.10 Activity tracking 58
3.4.2.11 Lock function (premium function) 58
3.4.2.12 System message 58
3.4.3 Control panel 59
3.4.4 Gear shift 60
3.4.4.1 SHIMANO SW-E7000 derailleur gears 60
3.4.4.2 ENVIOLO hub gear 61
3.4.5 Hand brake 62
3.4.6 Battery level indicator (battery) 63
3.4.6.1 Battery level indicator (battery) 63
3.5 Technical data 64
3.5.1 Pedelec 64
3.5.2 Emissions 64
3.5.3 Bicycle lighting 64
3.5.4 BOSCH Kiox on-board computer 64
3.5.5 USB port 64
3.5.6 Motor 64
3.5.6.1 BOSCH Active Line 64
3.5.6.2 BOSCH Active Line Plus 65
3.5.6.3 BOSCH Performance Line 65
3.5.6.4 BOSCH Performance Line CX 65
3.5.7 Rechargeable battery 65
3.5.7.1 BOSCH PowerPack 300 65
3.5.7.2 BOSCH PowerPack 400 65
3.5.7.3 BOSCH PowerPack 500 65
3.5.7.4 BOSCH PowerTube 400 66
3.5.7.5 BOSCH PowerTube 500 66
3.5.7.6 BOSCH PowerTube 625 66
3.5.8 BOSCH Pedelec ABS BAS100 66
3.5.9 Tightening torques 67
4 Transporting and storing
4.1 Weight and dimensions for transportation 69
4.2 Designated handles, lifting points 69
4.3 Transportation 70
4.3.1 Using the brake transport securing system 70
4.3.2 Transporting the pedelec 70
4.3.3 Shipping a pedelec 70
4.3.4 Transporting the battery 70
4.3.5 Shipping the battery 70
4.4 Storing 71
4.4.1 Break in operation 71
4.4.1.1 Preparing a break in operation 71
4.4.1.2 Carrying out a break in operation 71
5 Assembly
5.1 Unpacking 72
5.2 Required tools 72
5.3 Commissioning 73
5.3.1 Checking the battery 73
5.3.2 Preparing the battery 74
5.3.2.1 Retrofitting the PowerTube adapter 74
5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 76
5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 77
5.3.3 Installing the wheel in the SUNTOUR fork 78
5.3.3.1 Screw-on axle (12AH2 and 15AH2) 78
5.3.3.2 20 mm cross axle 79
5.3.3.3 Q-LOC quick release 81
5.3.4 Preparing the wheel 82

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Contents
5.3.5 Preparing the LIMOTEC seat post 83
5.3.6 Fitting the pedals 84
5.3.7 Checking the stem and handlebars 85
5.3.7.1 Checking the connections 85
5.3.7.2 Checking stem is firmly in position 85
5.3.7.3 Checking the headset backlash 85
5.4 Pedelec sale 85
6 Operation
6.1 Risks and hazards 86
6.2 Tips for a greater range 88
6.3 Error message 89
6.3.1 On-board computer 89
6.3.2 Rechargeable battery 92
6.4 Instruction and customer service 93
6.5 Adjusting the pedelec 93
6.5.1 Preparing 93
6.5.2 Pedelec adjustment procedure 94
6.5.3 Determining the sitting position 95
6.5.4 Adjusting the saddle 97
6.5.4.1 Straightening the saddle 97
6.5.4.2 Adjusting the saddle height 97
6.5.4.3 Setting the saddle height with the remote control 98
6.5.4.4 Adjusting the saddle position 99
6.5.4.5 Adjusting the saddle tilt 99
6.5.4.6 Checking saddle stability 99
6.5.5 Handlebars 100
6.5.5.1 Handlebar width 100
6.5.5.2 Hand position 100
6.5.5.3 Adjusting the handlebars 100
6.5.6 Stem 101
6.5.6.1 Adjusting the handlebar height with quick release 101
6.5.6.2 Setting the quill stem 102
6.5.6.3 Adjusting the Ahead stem 102
6.5.6.4 Adjusting the angle-adjustable stem 103
6.5.7 Ergonomic handles 104
6.5.7.1 Checking handlebar stability 104
6.5.8 Tyres 105
6.5.9 Brake 106
6.5.9.1 Brake handle position 106
6.5.9.2 Brake handle tilt angle 106
6.5.9.3 Determining the grip distance 107
6.5.9.4 Pressure point on a MAGURA brake lever 108
6.5.9.5 Grip distance on a MAGURA disc brake lever 109
6.5.9.6 Retracting the brake linings 110
6.5.10 Lighting 111
6.5.10.1 Adjusting the lights 111
6.5.11 Suspension 113
6.5.12 Fork sag 113
6.5.12.1 Adjusting the Suntour fork steel suspension 114
6.5.12.2 Adjusting the Suntour fork air suspension 115
6.5.12.3 Adjusting the ROCKSHOX fork coil spring with spacer for pre-tensioning 116
6.5.12.4 Adjusting the RockShox coil spring with an external preload adjuster 118
6.5.12.5 ROCKSHOX Paragon Silver coil spring 119
6.5.12.6 Adjusting the RockShox fork air suspension 121
6.5.13 Adjust the rear frame damper sag 123
6.5.13.1 Adjusting the RockShox rear frame damper 124
6.5.14 Fork rebound damping 126
6.5.14.1 Adjusting the Suntour fork rebound damping 127

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Contents
6.5.14.2 Adjusting the RockShox suspension fork 128
6.5.15 Adjusting the rear frame damper rebound damper 129
6.5.15.1 Adjusting the RockShox rear frame damper 130
6.5.16 Compression adjuster on rear frame damper 131
6.5.16.1 Adjusting the RockShox compression adjuster 132
6.5.17 Adjust on-board computer 133
6.5.17.1 Creating a user account 133
6.5.17.2 Connecting the on-board with the smartphone 133
6.5.17.3 Update pedelec software 133
6.5.17.4 Activating activity tracking 133
6.5.17.5 Setting up the lock function (optional) 133
6.5.17.6 Inserting the on-board computer 134
6.5.17.7 Securing the on-board computer 135
6.5.17.8 Removing the on-board computer 135
6.5.17.9 Operating the on-board computer 136
6.5.17.10 Opening the start screen 136
6.5.17.11 Opening the screens 136
6.5.17.12 Opening the quick menu 136
6.5.17.13 Opening the status screen 136
6.5.17.14 Adjust on-board computer 137
6.5.17.15 Selects the language 137
6.5.17.16 Adjusting the time 137
6.5.17.17 Setting the time zone 137
6.5.17.18 Setting the clock format 138
6.5.17.19 Setting the date 138
6.5.17.20 Selecting the unit of speed 138
6.5.17.21 Setting the brightness 138
6.5.17.22 Selecting the backlight 138
6.5.17.23 Configuring eShift 138
6.5.17.24 Resetting daily mileage or average values manually 138
6.5.17.25 Resetting daily mileage or average values automatically 138
6.5.17.26 Resetting the range 139
6.5.17.27 Resetting to factory settings 139
6.5.18 Connect external devices 139
6.5.18.1 Switching on Bluetooth® 139
6.5.18.2 Switching off Bluetooth® 139
6.5.18.3 Adding device to Bluetooth® 139
6.5.18.4 Removing device from Bluetooth® 139
6.6 Accessories 140
6.6.1 Child seat 140
6.6.2 Trailer 141
6.6.2.1 Trailer approval for ENVIOLO hub gear 141
6.6.3 Mobile holder 142
6.6.4 Tubeless and airless 142
6.7 Personal protective equipment and accessories for road safety 143
6.8 Before each ride 143
6.9 Straightening the quickly adjustable stem 144
6.10 Using the pannier rack 144
6.11 Raising the kickstand 145
6.12 Using the saddle 145
6.12.1 Using the leather saddle 145
6.13 Using the pedals 145
6.14 Using the multifunctional handlebars or bar ends 145
6.14.1 Using leather handles 145
6.15 Using the bell 145
6.16 Using the battery 146
6.16.1 Frame battery 146
6.16.1.1 Removing the frame battery 146
6.16.1.2 Inserting the frame battery 146

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Contents
6.16.2 Pannier rack battery 146
6.16.2.1 Removing the pannier rack battery 146
6.16.2.2 Inserting the pannier rack battery 146
6.16.3 Integrated battery 147
6.16.3.1 Removing the integrated battery 147
6.16.3.2 Inserting the integrated battery 147
6.16.4 Charging the battery 148
6.16.5 Charging the dual battery 148
6.16.5.1 Charging process when two batteries are used 148
6.16.5.2 Charging process when one battery is used 148
6.16.6 Using double battery model with a single battery only 149
6.16.7 Waking the battery 149
6.17 Using pedelec with the electric drive system 150
6.17.1 Switching on the electric drive system 150
6.17.2 Switching off the electric drive system 150
6.18 On-board computer 151
6.18.1 Deactivating the lock function 151
6.18.2 Switching on the on-board computer 151
6.18.3 Switching off the on-board computer 151
6.18.4 Using the USB port 152
6.18.5 Using the riding light 152
6.18.6 Using the push assist system 153
6.18.7 Selecting the level of assistance 154
6.19 Brake 155
6.19.1 Using the brake lever 155
6.19.2 Using the back-pedal brake 155
6.20 Suspension and damping 156
6.20.1 Adjusting the Suntour compression adjuster 157
6.20.1.1 Adjusting the RockShox compression adjuster 158
6.21 Gear shift 159
6.21.1 Using the derailleur gears 159
6.21.2 Using an ENVIOLO gear shift gear 160
6.21.2.1 Selecting automatic or manual shift 160
6.21.3 Switching gear in automatic mode 160
6.21.3.1 Switching gear manually 161
6.21.4 Using a SHIMANO hub gear 162
6.21.5 Using eShift 163
6.21.5.1 eShift with SHIMANO DI2 automatic hub gears 163
6.21.5.2 eShift with manual SHIMANO DI2 hub gears 163
6.21.5.3 eShift with SHIMANO DI2 automatic hub gears 163
6.22 Parking 164
6.22.1 Screwing in the quickly adjustable stem 165
6.22.2 Activating the lock function 166
7 Cleaning, servicing and maintenance
7.1 Before each ride 171
7.1.1 Checking the guards 171
7.1.2 Checking the frame 171
7.1.3 Checking the fork 171
7.1.4 Checking the rear frame damper 171
7.1.5 Checking the pannier rack 171
7.1.6 Checking the guards 171
7.1.7 Checking wheel concentricity 171
7.1.8 Checking the quick releases 171
7.1.9 Checking the suspension seat post 171
7.1.10 Checking the bell 172
7.1.11 Checking the handles 172
7.1.12 Checking the USB cover 172
7.1.13 Checking the lighting 172

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Contents
7.1.14 Checking the brake 172
7.2 After each ride 173
7.2.1 Cleaning the lights and reflectors 173
7.2.2 Cleaning the suspension fork 173
7.2.3 Caring for the suspension fork 173
7.2.4 Cleaning the pedals 173
7.2.5 Cleaning the brake 173
7.2.6 Cleaning the suspension seat post 173
7.2.7 Cleaning the rear frame damper 173
7.3 Basic cleaning 174
7.3.1 On-board computer and control panel 174
7.3.2 Rechargeable battery 174
7.3.3 Motor 174
7.3.4 Frame, fork, pannier rack, guards and kickstand 175
7.3.5 Stem 175
7.3.6 Handlebars 175
7.3.7 Handles 175
7.3.7.1 Leather handles 175
7.3.8 Seat post 175
7.3.9 Saddle 175
7.3.9.1 Leather saddle 176
7.3.10 Tyres 176
7.3.11 Spokes and spoke nipples 176
7.3.12 Hub 176
7.3.13 Switching elements 176
7.3.13.1 Shifter 176
7.3.14 Cassette, chain wheels and front derailleur 176
7.3.15 Brake 177
7.3.15.1 Brake lever 177
7.3.16 Brake disc 177
7.3.17 Belt 177
7.3.18 Chain 177
7.3.18.1 Chain with all-round chain guard 177
7.4 Servicing 178
7.4.1 Frame 178
7.4.2 Fork 178
7.4.3 Pannier rack 179
7.4.4 Mudguard 179
7.4.5 Servicing the kickstand 179
7.4.6 Stem 179
7.4.7 Handlebars 179
7.4.8 Handle 179
7.4.8.1 Rubber handles 179
7.4.8.2 Leather handle 180
7.4.9 Seat post 180
7.4.9.1 Suspension seat post 180
7.4.9.2 Carbon seat post 180
7.4.10 Leather saddle 180
7.4.11 Hub 180
7.4.12 Spoke nipples 180
7.4.13 Rim 180
7.4.14 Gear shift 181
7.4.14.1 Rear derailleur articulated shafts and jockey wheels 181
7.4.14.2 Shifter 181
7.4.15 Pedal 181
7.4.16 Caring for the chain 181
7.4.16.1 Caring for the chain and all-round chain guard 181
7.4.17 Caring for the brake 182
7.4.17.1 Caring for the brake 182

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Contents
7.4.18 Lubricating the eightpins seat post tube 182
7.5 Maintenance 183
7.5.1 Wheel 183
7.5.1.1 Checking the tyre pressure 183
7.5.1.2 Checking the tyres 185
7.5.1.3 Checking the rims 186
7.5.1.4 Checking the nipple holes 186
7.5.1.5 Checking the nipple well 186
7.5.1.6 Checking the rim hooks 186
7.5.1.7 Checking the spokes 186
7.5.2 Checking the brake system 187
7.5.2.1 Checking the hand brake 187
7.5.2.2 Checking the hydraulic system 187
7.5.2.3 Checking the Bowden cables 187
7.5.2.4 Checking the disc brake 188
7.5.2.5 Checking the back-pedal brake 189
7.5.2.6 Checking the rim brake 190
7.5.3 Checking the lighting 191
7.5.4 Checking the stem 192
7.5.5 Check the handlebars 192
7.5.6 Checking the saddle 192
7.5.7 Checking the seat post 192
7.5.8 Checking the chain 192
7.5.9 Checking the chain and belt tension 192
7.5.9.1 Checking the derailleur gears 193
7.5.9.2 Checking the hub gear 193
7.5.10 Checking the gear shift 193
7.5.10.1 Electric gear shift 193
7.5.10.2 Mechanical gear shift 193
7.5.10.3 Checking the derailleur gears 193
7.5.11 Adjusting gear shift 194
7.5.11.1 ROHLOFF hub 194
7.5.12 Bowden-cable-operated gear shift, single-cable 194
7.5.13 Bowden-cable-operated gear shift, dual-cable 194
7.5.14 Bowden-cable-operated twist grip, dual-cable 195
7.5.15 Checking kickstand stability 195
8 Maintenance
8.1 Initial inspection 196
8.2 Maintenance 196
8.3 Component-specific maintenance tasks 196
8.4 Carry out initial inspection 199
8.5 Maintenance instructions 200
8.5.1 Servicing the frame 207
8.5.1.1 Servicing the carbon frame 207
8.5.2 Checking the pannier rack 207
8.5.3 Servicing axle with quick release 207
8.5.4 Maintaining the stem 208
8.5.5 Servicing the gear hub 208
8.5.5.1 Adjusting the hub with cone bearing 208
8.5.6 Servicing the steering headset 209
8.5.7 Servicing the fork 209
8.5.7.1 Servicing the carbon suspension fork 210
8.5.7.2 Servicing the suspension fork 210
8.5.8 Servicing seat post 211
8.5.8.1 Servicing the carbon seat post 211
8.5.8.2 by.schulz suspension seat post 212
8.5.8.3 Suntour suspension seat post 212
8.5.8.4 Eightpins NGS2 seat post 213

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Contents
8.5.8.5 Eightpins H01 seat post 219
8.5.9 Rear frame damper 223
8.5.9.1 FOX component-specific maintenance 224
9 Troubleshooting, fault clearance and repair
9.1 Troubleshooting and fault clearance 225
9.1.1 Drive system or on-board computer does not start up 225
9.1.2 Error message 225
9.1.3 Errors in the assistance function 226
9.1.4 Battery errors 227
9.1.5 On-board computer errors 228
9.1.6 Lighting does not work 228
9.1.7 Other errors 229
9.1.8 Suntour suspension fork 230
9.1.8.1 Rebound too fast 230
9.1.8.2 Rebounding too slowly 231
9.1.8.3 Suspension too soft on inclines 232
9.1.8.4 Excessively hard damping on bumps 233
9.1.9 RockShox suspension fork 234
9.1.9.1 Rebound too fast 234
9.1.9.2 Rebounding too slowly 235
9.1.9.3 Suspension too soft on inclines 236
9.1.9.4 Excessively hard damping on bumps 237
9.1.10 Rear frame damper 238
9.1.10.1 Rebound too fast 238
9.1.10.2 Rebounding too slowly 239
9.1.10.3 Suspension too soft on inclines 240
9.1.10.4 Excessively hard damping on bumps 241
9.1.11 RockShox rear frame damper 242
9.1.11.1 Rebound too fast 242
9.1.11.2 Rebounding too slowly 243
9.1.11.3 Suspension too soft on inclines 244
9.1.11.4 Excessively hard damping on bumps 245
9.2 Repair 246
9.2.1 Original parts and lubricants 246
9.2.2 Replacing the lighting 246
9.2.3 Setting the front light 246
9.2.4 Checking tyre clearance 246
9.2.5 Replacing pedelec components if lock function is installed 247
9.2.5.1 Replacing a smartphone 247
9.2.5.2 Replacing the on-board computer 247
9.2.5.3 Activating the lock function after motor replacement 247
10 Recycling and disposal
10.1 Removal of waste guidelines 248
11 Documents
11.1 Assembly report 250
11.2 Maintenance log 252
11.3 Parts list 256
11.3.1 Quadriga Duo CX5 256
11.3.2 Quadriga Duo CX10 258
11.3.3 Quadriga Duo CX12 260
11.3.4 Quadriga Duo CX12 FS 262
11.3.5 Quadriga Duo CX12 FS SUV 264
11.3.6 Quadriga Duo E-TR Belt 266
11.3.7 Quadriga Pro Belt 268
11.4 Charger operating instructions 270