Kettler Comfort Quick guide

EN
ELECTRIC BICYCLES
877-00136 • 1.0 • 13 September 2018
TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
Comfort, Escaro Comp 8, Escaro Cross, EscaroPro,
Quadriga Cityhopper, Quadriga CX, Quadriga Cross,
Quadriga Plus, Quadriga
KB065-VAKxxx, KB065-VBKxxx, KB065-VCKxxx, KB066-VAFxxx, KB066-VBFxxx, KB066-VCFxxx,
KB068.VAFxxx, KB068-VARxxx, KB069-VAFxxx, KB070-VAKxxx, KB070-VBKxxx, KB076-VAFxxx,
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE FOR LATER REFERENCE
EN_877-00136_1.0_0.01_09.18_KETTLER Suntour MY19_COVER.book Page 1 Thursday, September 13, 2018 12:56 PM

Copyright
© ZEG Zweirad-Einkaufs-Genossenschaft eG
Distribution or reproduction of these operating instructions
and utilisation or communication of their content is prohibited
unless expressly approved. Any infringement will render the
offender liable for compensation. All rights reserved in the
event that a patent, utility model or industrial design is
registered.
EN_877-00136_1.0_0.01_09.18_KETTLER Suntour MY19_COVER.book Page 3 Thursday, September 13, 2018 12:56 PM

877-00136_1.0_17.09.2018 1
Data sheet
Surname, first name of the purchaser:
Date of purchase:
Model:
Frame number:
Type number:
Unladen weight (kg):
Tyre size:
Recommended tyre pressure (bar)*: front: rear:
Wheel circumference (mm):
Company stamp and signature:
*After a tyre change, refer to the tyre markings for the permitted tyre
pressures and make sure that they are observed. The recommended tyre
pressure must not be exceeded.

Table of contents
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2
Table of contents
1 About these instructions 7
1.1 Manufacturer 7
1.2 Laws, standards and directives 8
1.3 Other valid documents 8
1.4 Subject to change 9
1.5 Language 9
1.6 For your safety 11
1.6.1 Instruction, training and customer service 11
1.6.2 Basic safety notes 12
1.6.3 Warnings 12
1.6.4 Safety markings 13
1.7 For your information 13
1.7.1 Instructions for actions 13
1.7.2 Information on the type plate 14
1.7.3 Language conventions 15
1.8 Type plate 17
1.9 Identifying 18
1.9.1 Operating instructions 18
1.9.2 Bicycle 18
2 Safety 20
2.1 Requirements for the rider 20
2.2 Hazards for vulnerable groups 20
2.3 Personal protective equipment 20
2.4 Proper use 21
2.4.1 City and trekking bicycle 21
2.5 Improper use 22
2.5.1 City and trekking bicycle 22
2.6 Duty to take care 23
2.6.1 Rider 23
3 Description 24
3.1 Overview 24
3.2 Handlebars 25
3.3 Wheel and fork 27
3.3.1 Valve 27
3.4 Brake system 29
3.5 Electric drive system 31
3.6 Drive system 31

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Table of contents
3.6.1 Battery 33
3.6.1.1 Operating and charge status indicator 34
3.6.2 Operating element with display 35
3.6.2.1 Level of assistance 36
3.6.2.2 Current speed 36
3.6.2.3 System message 36
4 Technical data 37
5 Transportation, storage and assembly 39
5.1 Transportation 39
5.1.1 Using the transport securing system 41
5.2 Storing 41
5.2.1 Break in operation 42
5.2.1.1 Preparing a break in operation 43
5.2.1.2 Taking out of operation 43
5.3 Assembly 44
5.3.1 Required tools 44
5.3.2 Unpacking 45
5.3.3 Scope of delivery 45
5.3.4 Commissioning 46
5.3.4.1 Checking the battery 48
5.3.4.2 Checking the stem and handlebars 49
5.3.5 Sale of the bicycle 50
6 Before the first ride 51
6.1 Adjusting the saddle 51
6.1.1 Adjusting the saddle tilt 51
6.1.2 Determining the seat height 52
6.1.3 Adjusting the seat height with quick release 53
6.1.4 Setting the height-adjustable seat post 55
6.1.4.1 Lowering the saddle 55
6.1.4.2 Raising the saddle 55
6.1.5 Adjusting the seat position 56
6.2 Setting the handlebars 57
6.2.1 Adjusting the handlebar height 58
6.2.2 Turning the handlebars to the side 59
6.2.2.1 Checking the clamping force of the quick releases 60
6.2.2.2 Adjusting the quick release clamping force 60
6.3 Adjusting the brake lever 60
6.3.1 Adjusting the pressure point on a Magura brake lever 60

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4
6.3.2 Adjusting the grip distance 61
6.3.2.1 Adjusting the grip distance on a Magura brake lever 62
6.4 Retracting brake linings 63
7 Operation 64
7.1 Before each ride 66
7.2 Check list before each ride 67
7.3 Using the kickstand 68
7.4 Battery 69
7.4.1 Integrated battery 71
7.4.1.1 Removing the integrated battery 71
7.4.1.2 Inserting the integrated battery 71
7.4.2 Charging the battery 72
7.4.3 Waking the battery 74
7.5 Electric drive system 75
7.5.1 Switching on the drive system 75
7.5.2 Switching off the drive system 75
7.6 Operating element with display 76
7.6.1 Selecting the level of assistance 76
7.7 Brakes 76
7.7.1 Using the brake 77
7.8 Gear shift 78
7.8.1 Using derailleur gears 78
7.9 Brake 79
7.9.1 Using the brake lever 83
7.9.2 Using the back-pedal brake 83
8 Maintenance 84
8.1 Cleaning and servicing 86
8.1.1 After every ride 86
8.1.1.1 Cleaning the suspension fork 86
8.1.1.2 Cleaning the rear frame damper 86
8.1.1.3 Cleaning the pedals 86
8.1.2 Basic cleaning 87
8.1.2.1 Cleaning the frame 88
8.1.2.2 Cleaning the stem 88
8.1.2.3 Cleaning the rear frame damper 88
8.1.2.4 Cleaning the wheel 88
8.1.2.5 Cleaning the drive elements 89
8.1.2.6 Cleaning the chain 89

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Table of contents
8.1.2.7 Cleaning the battery 90
8.1.2.8 Cleaning the drive unit 90
8.1.2.9 Cleaning the display 91
8.1.2.10 Cleaning the brake 91
8.1.3 Servicing 92
8.1.3.1 Servicing the frame 92
8.1.3.2 Servicing the stem 92
8.1.3.3 Servicing the fork 92
8.1.3.4 Servicing the drive elements 92
8.1.3.5 Servicing the pedal 92
8.1.3.6 Servicing the chain 92
8.1.3.7 Servicing the drive elements 93
8.2 Maintenance 94
8.2.1 Wheel 94
8.2.2 Brake system 95
8.2.3 Electrical cables and brake cables 95
8.2.4 Gear shift 95
8.2.5 Stem 96
8.2.6 Checking the chain and belt tension 96
8.2.7 USB port 97
8.2.8 Suspension fork 97
8.3 Service 98
8.4 Adjusting and repairing 100
8.4.1 Use original parts and lubricants only 100
8.4.2 Wheel quick release 101
8.4.2.1 Clamping the quick release 102
8.4.3 Adjusting the tyre pressure 104
8.4.3.1 Dunlop valve 104
8.4.3.2 Presta valve 105
8.4.3.3 Schrader valve 106
8.4.4 First aid for system messages 107
8.4.4.1 First aid 107
8.4.4.2 Specific error eradication 108
8.5 Accessories 109
8.5.1 Child seat 110
8.5.2 Bicycle trailer 111
8.5.3 Pannier rack 112

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9 Recycling and disposal 114
10 Appendix 116
10.1 EC declaration of conformity 116
10.2 Parts list 117
10.3 Table of figures 120
10.4 Subject index 123

877-00136_1.0_17.09.2018 7
About these instructions
1 About these instructions
Read these operating instructions before
commissioning the bicycle to ensure you use all the
functions correctly and safely. The operating
instructions are not a substitute for personal
instruction by the supplying specialist dealer. The
operating instructions are a component part of the
bicycle. Therefore, if it is re-sold at a later time, they
must be handed over to the subsequent owner.
These operating instructions are mainly directed at the
rider and operator of the cycle. In general, they are
technical laypersons
Text passages which are expressly intended for
specialist staff (e.g. bicycle mechanics) are clearly
marked with a tool symbol.
.
Staff at all specialist dealers have specialist training
and qualifications, and are therefore capable of
identifying risks and preventing hazards which may
arise during maintenance, servicing and repairs on the
bicycle. Information for specialist staff does not require
non-professionals to take any action.
1.1 Manufacturer
The manufacturer of the bicycle is:
KETTLER Alu-Rad GmbH
Longericher Straße 2
50739 Köln, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.kettler-alu-rad.de

About these instructions
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8
1.2 Laws, standards and directives
These operating instructions comply with the essential
requirements from:
• the Machinery Directive 2006/42/EC,
• Electromagnetic Compatibility Directive 2014/30/EU,
• EN ISO 12100:2010 Safety of machinery – General
principles of design – Risk assessment and reduction,
•EN15194:2015, Cycles – Electrically power assisted
cycles – EPAC bicycles,
• EN ISO 4210, Cycles – Safety requirements for
bicycles
•EN11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods,
•EN82079-1:2012, Preparation of instructions for use
– Structuring, content and presentation – Part 1:
General principles and detailed requirements,
• EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
1.3 Other valid documents
These operating instructions are only complete in
conjunction with the other valid documents.
The following document applies for this product:
• Charger operating instructions.
No other information is also applicable.
The constantly updated lists of approved accessories
and parts are available to specialist dealers.

877-00136_1.0_17.09.2018 9
About these instructions
1.4 Subject to change
The information contained in these operating
instructions are the approved technical specifications
at the time of printing. Any significant changes are
included in a new issue of the operating instructions.
You will find any modifications to these operating
instructions at:
www.kettler-alu-rad.de/de/de/index/service/anleitung
1.5 Language
The original operating instructions are written in
German. A translation is not valid without the original
operating instructions.

About these instructions
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11
1.6 For your safety
The safety concept of the bicycle comprises four
elements:
• rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer,
• the chapter on general safety,
• the warnings in these instructions and
• the safety marking on the type plates.
1.6.1 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 in the data sheet. If
you are unable to contact your specialist dealer, you
will find other specialist dealers to attend to your
customer service needs on www.kettler-alu-rad.de.
The specialist dealer authorised to perform repairs and
maintenance work receives regular training.
The rider or the operator of the bicycle will be
instructed in person on the bicycle functions when the
supplying specialist dealer hands over the bicycle, if
not before. This instruction particularly covers the
bicycle's electrical functions and correct use of the
charger.
Each rider to whom this bicycle is provided must
receive instruction on the bicycle's functions. The
operating instructions must be submitted to each rider
in printed form and must be acknowledged and
adhered to.

877-00136_1.0_17.09.2018 12
About these instructions
1.6.2 Basic safety notes
These operating instructions have a chapter with
general safety notes. You can distinguish this chapter
as it has a grey background.
1.6.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating instructions
are shown as follows:
SIGNAL WORD
Type and source of the danger
Description of the danger and the consequences.
Measures
The following pictograms and signal words are used in
the operating instructions for warnings and information
notices:
Table 1: Meanings of the signal words
GEFAHR
DANGER
!Will lead to serious or even fatal injuries if ignored.
High-risk hazard.
WARNING
!May lead to serious or even fatal injuries if ignored.
Medium-risk hazard.
CAUTION
!May lead to minor or moderate injuries. Low-risk
hazard.
NOTICE May lead to material damage if ignored.

About these instructions
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1.6.4 Safety markings
The following safety markings are used on the
bicycle's type plates:
Table 2: Safety markings on the product
General warning
Adhere to the instructions for use
1.7 For your information
1.7.1 Instructions for actions
Instructions for actions are structured in accordance
with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)

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About these instructions
1.7.2 Information on the type plate
Alongside the warnings, the type plates of the
products also contain other important information on
the bicycle:
Table 3: Area of use
only suitable for the road, no off-road riding or jumps
suitable for roads, off-road riding and jumps of up to
15 cm
suitable for rough off-road riding and jumps of up to
61 cm
suitable for rough off-road riding and jumps of up to
122 cm
suitable for the most difficult terrain
Table 4: Bicycle type
City and trekking bicycle
Child's bicycle / bicycle for young adults
BMX bicycle
Mountain bike
Racing bicycle
Carrier bicycle
Folding bicycle

Table 5: Information on the type plate
Read the instructions
Separate collection of electrical and electronic
devices
Separate collection of batteries
Must not be thrown into fire (burning prohibited)
Must not be thrown into water (immersed)
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
About these instructions
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1.7.3 Language conventions
The bicycle described in these operating instructions
may be equipped with alternative components. The
equipment of the bicycle is defined by the respective
type number [Table 3, page 14]. If applicable, the
notes alternative equipment and alternative version
make reference to the use of alternative components.
Alternative equipment describes additional components
which are not necessarily an integral part of every
bicycle in these instructions.

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About these instructions
Alternative version explains the various variants of
components if they differ in use.
The following terms are used for better legibility:
Table 6: Simplified terms
Term Meaning
Operating
instructions
Original operating instructions
or translation of the original
operating instructions
Bicycle Electric motor driven cycle
Motor Drive motor
The following conventions are used in these operating
instructions:
Table 7: Conventions
Convention Use
Italics Entry in the index
SPACED Displays on the display
screen
[Example, page
numbering]
Cross references
•Bulleted lists

About these instructions
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1.8 Type plate
The type plate is situated on the frame. The type plate
features the following information:
KETTLER
Alu-Rad GmbH
Longericher Str. 2
50739 Köln, Germany
Typ:
19-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2018 / MJ 2019
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
Figure 1: Type plate, example
1 CE marking
2 Manufacturer
3 Type number
4 Nominal continuous power
5 Permitted total weight
6 Year of manufacture
7Bicycle type
8Safety instructions
9Disposal instruction
10 Area of use
11 Model year
12 Weight of the ready-to-ride bicycle
13 Shut-off speed

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About these instructions
1.9 Identifying
1.9.1 Operating instructions
The identification number of these operating
instructions is made up of the document number, the
version number and the release date. It can be found
on the cover page and in the footer.
Table 8: Identification number of the operating instructions
Identification number 877-00136_1.0_17.09.2018
1.9.2 Bicycle
These KETTLER operating instructions refer to the
model year 2019. The production period is from August
2018 to July 2019. They are issued in August 2018.
The operating instructions are a component part of the
following bicycles:
Type number Model Bicycle type
KU117-VAFD50 2° E Beltdrive City and trekking bicycle
KU117-VAFD55 2° E Beltdrive City and trekking bicycle
KU117-VAFD60 2° E Beltdrive City and trekking bicycle
KU117-VAFT45 2° E Beltdrive City and trekking bicycle
KU117-VAFT50 2° E Beltdrive City and trekking bicycle
KU118-VAFD50 2° E Street Beltdrive City and trekking bicycle
KU118-VAFD55 2° E Street Beltdrive City and trekking bicycle
KU118-VAFD60 2° E Street Beltdrive City and trekking bicycle
KU118-VAFT45 2° E Street Beltdrive City and trekking bicycle
KU118-VAFT50 2° E Street Beltdrive City and trekking bicycle
KU119-VAFD50 2° E Comp City and trekking bicycle
KU119-VAFD55 2° E Comp City and trekking bicycle
KU119-VAFD60 2° E Comp City and trekking bicycle
KU119-VAFT45 2° E Comp City and trekking bicycle
KU119-VAFT50 2° E Comp City and trekking bicycle
KU120-VAFD50 2° E Carbon City and trekking bicycle
KU120-VAFD55 2° E Carbon City and trekking bicycle
KU120-VAFD60 2° E Carbon City and trekking bicycle
KU120-VAFT45 2° E Carbon City and trekking bicycle
KU120-VAFT50 2° E Carbon City and trekking bicycle

About these instructions
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KU121-VAFD46 2° E Compact City and trekking bicycle
KU159-VAKD50 2° E Comp Street City and trekking bicycle
KU159-VAKD55 2° E Comp Street City and trekking bicycle
KU159-VAKD60 2° E Comp Street City and trekking bicycle
KU159-VAKT45 2° E Comp Street City and trekking bicycle
KU159-VAKT50 2° E Comp Street City and trekking bicycle
Type number Model Bicycle type