KTM BDU3740 User manual

supplementing
theORIGINAL
OPERATING
INSTRUCTIONS
EPAC
ENGLISH

English – Page 1
General instructions
Congratulations! You have made a good decision by buying this quality bicycle made by KTM. We are convinced that your
new bicycle will do more than just satisfy your expectations in regard to functionality, design and quality. All of our bikes
are manufactured using premium materials and state-of-the-a technology and come equipped with only the best compo-
nents. Your bicycle was assembled by the KTM dealer and then subjected to rigorous functional tests.
Explanation of symbols:
DANGER: Indicates a clear and imminent danger. The situation will lead to death or serious injury if it is not
aveed.
WARNING: Indicates a possible imminent danger. The situation may lead to death or serious injury if it is not
aveed.
NOTE/CAUTION: Indicates a possibly damaging situation. Your bicycle or its surroundings may be damaged if
the situation is not aveed.
Make sure that your new EPAC (Electrically Power Assisted Cycle) was fully assembled, adjusted and handed over to you by
KTM with all necessary descriptions.
This “Supplement to the Original Operating Instructions” adds to the “Original Operating Instructions” and contains informa-
tion relating specifically to the EPAC. It is divided into the following sections:
General instructions ..................... 1
Detailed view – EPAC .................... 2
EPAC drive system ...................... 3
Legal bases.............................. 3
Safety instructions ...................... 4
Safety instructions for child EPACs ........ 5
General instructions ..................... 5
Conformity .............................. 5
Cleaning and care ........................ 6
Maintenance and repairs.................. 6
Disposal ................................. 7
Transpo and loading...................... 7
Range.................................... 8
KTM Declaration of Conformity.............. 9
Drive Unit ............................... 10
Kiox 300 Bordcomputer ................... 14
Display Mount ........................... 18
LED Remote .............................. 22
Poweube .............................. 27
Charger ................................. 33

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1 Top tube 8 Fork 15 Propulsion 22 Rear derailleur 29 Saddle clamp 36 Chain guard
2 Headset 9 Spokes 16 Drive unit cover 23 Sprocket 30 Seat post 37 Head light
3Stem 10 Rim 17 Pedal 24 Derailleur hanger 31 Saddle 38 Tail light
4On-board
computer 11 Tyre 18 Cotterless right
crank 25 Back brake 32 Battery 39 Racks
5Handlebars 12 Valve 19 Bottom bracket 26 Seat stay 33 Battery lock 40 Stand
6 Brake lever 13 Front brake 20 Chain 27 Speed sensor 34 Shocks
7 Head tube 14 Down tube 21 Chain stay 28 Seat post 35 Rocker
Detailed view – EPAC
EPAC – Full Suspension Mountain Bike (representative image)
EPAC – Trekking Onroad (representative image)
4

English – Page 3
EPAC drive system
All KTM bicycles that are fitted with an electric drive system are EPACs (Electrically Power Assisted Cycles) as defined in
EN 15194. Their main distinctive features compared to a bicycle without propulsion assistance are the installation of an on-
board computer, battery and drive unit. The following pages provide detailed descriptions of all components that are used
in connection with the drive system. In the following, the motor is also described as a drive unit, the battery as a power
pack or power tube, the display as an on-board computer and the charging device as a charger. The term e-bikes is also
used for EPACs.
Exclusively original drive components and original batteries by the individual manufacturers are used in KTM
EPACs. You should therefore use only original pas from the relevant manufacturer for retrofitting and re-
placement purposes. The use of third-pay or unsuitable drive components and batteries can cause the
battery to overheat, ignite or even explode. This would void all warranty and guarantee claims for the drive
system.
EPAC drive components from dierent model years only show limited compatibility. Never try to install incompatible drive
components by force. Doing so would place you and others at risk. It would void all warranty and guarantee claims relating
to the drive system.
Under no circumstances may EPACs with fully-integrated down tube batteries be operated without the battery cover
closed.
Legal bases
The mandatory conditions that must be adhered to are inferred from the following standards/regulations:
· DIN EN 15194 / Bicycles – electrically power assisted cycles – EPAC bicycles
· Machinery Directive 2006/42/EC
· DIN EN ISO 4210-2 / Cycles – Safety requirements for bicycles – Pa 2: Requirements for city and trekking, young adult,
mountain and racing bicycles
· The national highway code in each country
￭ Maximum continuous rating must not exceed 250W. (Brief maximum power up to 600W)
￭ The drive unit may only provide assistance when the rider is pedalling.
￭ The maximum pedal assist speed is 25 km/h. Drive unit power must decrease as the speed increases.
￭ A push aid that automatically accelerates the EPAC must only work up to 6 km/h.
￭ Helmets are not mandatory. You should nonetheless wear a tested bicycle helmet in the interests of your own safety.
￭ A driving license is not required.
￭ Insurance is not required.
￭ You may use cycleways in the same way as you would with a normal bicycle.
￭ All KTM EPACs are designed for persons aged 14 and older. Child EPACs are an exception. All KTM EPACs are designed
for persons aged 8 and older, provided they have received thorough instruction.
These regulations essentially apply throughout the European Union. But please take note that additional national laws may
be in place to regulate the use of EPACs. Other conditions may apply in non-EU countries in Europe.

English – Page 4
Safety instructions
￭ The use of electronic components in a KTM EPAC may lead to additional hazards under ceain
circumstances. You must therefore read all safety instructions and keep them in a safe place for
future reference. A failure to comply with the safety instructions can cause electric shocks, fire and/
or severe injuries.
￭ Do not make any modifications or changes, neither to the hardware nor to the soware. This can cause
unpredictable, dangerous situations, accidents or falls that lead to injuries.
￭ Always charge the battery in a dry place and never close to easily flammable or combustible materials.
Also keep metallic/electrically conductive objects away from the battery of your EPAC, as they may
cause a sho circuit if they touch the contacts of the battery and therefore increase the fire risk
considerably.
￭Take care in connection with pacemakers and medical devices.
This EPAC has been tested according to all valid and mandatory standards for EPACs. Nonetheless, this EPAC is not a
special device that was manufactured according to medical requirements. In order to prevent possible malfunctions
of your pacemaker or medical device, please consult your attending specialist or the manufacturer of the individual
medical device before using the EPAC.
￭Emitted sound pressure level
The A-weighted emission sound pressure level measured at the driver’s ears is less than 70 dB(A)
￭Tuning
Tuning means measures that are intended to increase performance or to exceed the speed limits of pedal assistance
delivered by the individual drive system. This is achieved by changing the parameters or using retrofit tuning kits.
Modifications of this kind are neither permitted nor recommended due to the strict legal conditions. These laws are in
place to prevent dangerous situations. These modifications may also considerably increase wear on the drive system
and components.
￭Do not ride the EPAC if the battery is dismantled
The battery is used to power the lighting, so driving with the battery removed will aect how the lighting works.
Failure to do so is an administrative oence and can lead to fines, loss of insurance or accidents and falls involving
injuries.
￭Do not attempt to exceed the maximum pedal assist speed or modify the riding characteristics by manipulating
the parameters.
Manipulation is an administrative oence and can lead to fines, loss of insurance or accidents and falls involving
injuries. It would void all warranty and guarantee claims.
Paicular care must be taken in the following situations due to the high torque of the drive system:
￭ Motor power may take eect abruptly when staing at a high suppo level. Avoid putting pressure on the pedals if
you are not seated properly on the bicycle or if you push o with one leg when setting o.
￭ Press the brakes for your own safety when getting onto the EPAC; this will prevent it from staing to move
unintentionally.
￭ Press the brakes for your own safety while the bicycle is stationary (waiting); this will prevent the EPAC from staing
to move unintentionally.

English – Page 5
Safety instructions for child EPACs
￭ Read all the safety instructions and familiarise your child with their contents. So keep these operating
instructions in a safe place for future reference. A failure to comply with the safety instructions can
cause electric shocks, fire and/or severe injuries.
￭ Electric shock is a moal danger. Cables must not be bent, compressed or damaged on sharp edges.
￭ The battery may ignite or even explode if its protective circuit and protective mechanism become dam-
aged. This may present a moal danger. Always remove the battery if you are performing maintenance,
repair or cleaning tasks.
￭Never leave your child unsupervised when using and handling the EPAC.
Familiarise your child with all functions before using the EPAC.
￭Give your child detailed instruction on how to use the EPAC.
Incorrect use cannot otherwise be ruled out.
￭Child EPACs are only suitable for use on asphalted cycleways and roads.
Use on the pavement is prohibited.
￭Never allow your child to handle or clean the EPAC with tools or bare hands.
￭Before each journey with your child, make sure that all components are adjusted correctly and that the screw
connections and quick release are closed tight.
Refer to the chapter on “Information about the operating instructions“, section “Before the first ride” and “Before
every ride”.
￭Make ceain that the frame size and operating elements are adjusted to the size of your child.
An incorrect frame size may negatively aect the operability and controllability of the EPAC – for instance, the rider
may be unable to operate the brakes properly.
￭Compared to a conventional EPAC, the following aspects were limited on the child EPAC to make sure that the safety
of your child is guaranteed at all times.
￭ The pedal assist speed was restricted to 20 km/h.
￭ The push aid function was disabled.
￭ The EPAC is initially in OFF mode when it is activated.
￭ The maximum permissible weight (rider + luggage) of a child EPAC is 50 kg.
General instructions
Please note removing a control panel or battery does not protect the bicycle against the. The drive components can be
used to operate your EPAC, even without the assist functions. You must therefore use a safe and tested bicycle lock to
attach your EPAC to a fixed object at all times (bicycle stand, etc.). Your KTM dealer will gladly assist you in selecting the
right bicycle lock.
Always remove the battery and keep it in a dry and under no circumstances unusually cold place (room temperature) if you
will do not intend to use the EPAC for a longer period.
Conformity
The complete KTM EU Declaration of Conformity is included in these instructions (refer to the “KTM Declaration of Conformity”
chapter). The complete Bosch EU Declarations of Conformity are available at the following Internet address: www.bosch-
ebike.com/conformity.

English – Page 6
Cleaning and care
￭Never use a high-pressure cleaner or steam jet to clean your complete EPAC.
The powerful water jet might damage the electrical drive components and the fine bushing on the other components.
Use a so sponge or a so brush to clean your EPAC. As a rule, work with only a little water and keep water away from
the electrical contacts. Aer cleaning, check the plug connections for moisture and allow them to dry before putting
the bicycle back into operation.
Careful cleaning of your EPAC significantly extends the service life of the individual components. Clean your
EPAC regularly as described above.
Maintenance and repairs
￭Only entrust your KTM dealer with repair and maintenance of the drive system.
Unprofessional maintenance and repair may damage the EPAC.
￭Always remove the battery before maintenance and repair.
There is otherwise a considerable risk of injury, as the system could sta up due to mechanical actions such as the
application of load to the chain or pedals, inadveently pressing the push aid and similar.
￭Be careful not to fold or compress cables when performing maintenance or repair on the EPAC, and make sure that
the cables are not damaged on sharp edges.
Damaged cables present a life-threatening risk of electric shock.
￭OnlyuseoriginalKTMcomponents,aswell as original drive components and batteries, forrepairsandreplacements.
You are advised to use only original KTM components to replace pas of your EPAC, as they must fulfil ceain
characteristics. You should also use only original drive components and batteries by the individual manufacturers.
The use of third-pay or unsuitable components may lead to breakage or failure that can cause accidents or falls
with injuries. The use of third-pay or unsuitable drive components and batteries can cause the battery to overheat,
ignite or even explode. This would void all warranty and guarantee claims relating to the drive system. Contact your
KTM dealer to select the right replacement components.
￭Bring your EPAC for its first inspection aer 200 km.
Screw connections may settle during the first kilometres of use. Ask your KTM dealer to check the spoke tension and
all screw connections aer the first 200 km. Refer to the chapter on “Maintenance and care intervals” in this regard.
Your EPAC will remain in a safe operational condition at all times if you adhere to the prescribed maintenance
and care intervals. The service life of its components will also be extended.
￭Be aware that the components of your EPAC are exposed to greater wear. All original spare pas can be purchased
from your KTM dealer.
All components, especially the chain, sprocket and brake components, are subject to increased wear due to the
additional exeion of force by the drive components and the greater weight of an EPAC. Shoer maintenance
intervals must therefore be observed, compared to a conventional bicycle. Poorly maintained or worn components
can lead to accidents or falls and then to injuries. Refer to the information in the chapter on “Maintenance and care
intervals” in this regard.
￭Please note that the drive components show slightly elevated resistance when pedalling and emit a quiet travelling
noise due to their technical design.
Elevated freewheel resistance and a quiet travelling noise do not necessarily indicate a technical defect and are
instead due to the technical design of the drive components. An increase in resistance or travelling noise during
operation may indicate a lack of maintenance. Simply contact your KTM dealer.

English – Page 7
￭You are urgently advised to make a note of the key number.
The key number can be noted on the last page of the original operating instructions in the bicycle registration
document and in the handover ceificate. If you lose the key, you can use the key number to order a replacement
from your KTM dealer.
Disposal
A used battery or defective electrical components must be disposed of properly.
Used batteries and electrical components, such as drive units, head lights, rear lamps and hub dynamos,
must not be placed with household waste – please recycle them or return them to a KTM dealer. For detailed
information on the disposal of EPAC components, refer to the chapter on the “Bosch drive system”.
Transpo and loading
￭ Overloading may cause the EPAC components to deform or break.
￭ The battery may ignite or even explode if its protective circuit and protective mechanism become
damaged. This may present a moal danger. For this reason, remove the battery when transpoing
it by car.
￭ Attach a cap or another safety appliance to protect the battery contacts from unintentional sho
circuit.
Never take a passenger on your EPAC (exception: carrying a small child in a child seat).
Pay attention to the maximum permissible weight – refer to the chapter on “Intended use”.
￭Make sure that you remove the battery before transpoing the EPAC by or in a car.
Contact with liquids can cause heat, fire, explosion and smoke due to damage to the protective circuit and protective
mechanism of the battery.
￭Adhere to the applicable regulations on hazardous goods when transpoing the battery.
Transpoing an EPAC battery may be legally classified as a transpo of hazardous goods. Familiarise yourself with the
applicable regulations on hazardous goods before transpoing the EPAC battery. Any violation of these regulations is
an administrative oence and can lead to fines.
￭Exclusively use suitable bike carriers (roof or tail racks) to transpo your EPAC by car.
Not all bicycle bike are suitable for the safe transpo of EPACs due to the position of the drive components, the
special frame shape and the increased weight of EPACs. When transpoing an EPAC, an unsuitable bike carrier may
be damaged or break and therefore cause accidents. An unsuitable bike carrier may also damage the EPAC. Aer
transpoing the EPAC by car, check the plug connections for moisture and allow them to dry before putting the
bicycle back into operation.
￭Be aware that driving characteristics may change significantly due to additional load.
Pay attention to the maximum permissible weight for your EPAC during loading – refer to the chapter on “Intended
use”. Keep the load symmetrical at all times.
￭Only use child seats that are suitable for mounting on your EPAC.
Driving characteristics may change significantly due to additional load – refer to the chapter on “Intended use”. Your
child should wear a tested child helmet.
￭Only use bicycle or child trailers that are suitable for attachment to your EPAC.
The position of the drive components and the special frame form mean that not all bicycle or child trailers are suitable
for attachment to the frame. You and your child may suer accidents with very severe injuries if you use an unsuitable
bicycle or child trailer. Your KTM dealer will gladly assist you in selecting a suitable trailer. Your child should wear a
tested child helmet at all times.

English – Page 8
Range
The anticipated range is calculated based on a maximum range value determined by KTM under real conditions (perfect
riding conditions) and depending on the load status, taking into account the current consumption. This calculations enables
the specification of a theoretical value. This value varies to a greater or lesser extent, depending on driving conditions. For
instance, the range will be significantly smaller when travelling in a hilly or mountainous region. Please take note, therefore,
that this indication can be used merely as a rough estimate for the achievable residual range.
The anticipated maximum range depends on a wide variety of circumstances. These factors include the selected suppo
level, rider’s weight, terrain, wind conditions, tyre pressure and ambient temperature. All range values indicated here refer
to ideal conditions.
Optimal/ideal conditions are: even/flat terrain without head wind, 20°C ambient temperature, paicularly narrow, treadless
tyres, driver weight under 70kg.
Factors that aect the range
1. Route topography: The energy required for navigating hilly terrain rises dispropoionately compared to riding on level
paths.
2. Selected suppo level: Always select the suppo level to suit your needs and with care.
3. Battery charge: Only a fully charged battery can guarantee the maximum range. So make sure that the battery is
recharged before each use.
4. Weight and load: The more weight that the bicycle carries (rider and luggage), the shoer the range.
5. Air pressure in the tyres: The tyres oer significant potential. Insufficient pressure causes higher rolling resistance
and therefore requires an extremely high energy input. The maximum permissible air pressure is printed directly on
the sidewalls of the tyres. Tyres with rough, heavy tread require a great deal of energy. Switching to smooth, narrow
tyres has a very favourable eect on the range.
6. Staing/accelerating from a stationary position: Drive systems require considerably more energy when staing
from a stationary position than when travelling continuously. Maintaining a constant speed or changing it only gently
can improve the range. Avoid exeing sudden, jerky pressure on the pedals.
7. External influences/weather: Managing headwind requires an enormous expenditure of energy. Heat and cold can
also drain the battery quickly.
8. Applied force: The range will be very small if you rely exclusively on the drive system for power.
9. Shiing gears: Use the gears actively, as you would with a normal bicycle. For instance, shi to a lower gear early
enough when you are travelling uphill. The drive unit can only operate eectively and efficiently at an ideal cadence
of 75 revolutions per minute. Slow pedalling leads to sudden assistance, causes the drive unit to overheat and will
drain the battery very quickly.
10. Charging external soware: Charging external hardware such as smaphones or MP3 players using the charger po
on the display can shoen the range accordingly.