Maxon BIKEDRIVE MX25 User manual

USER MANUAL
Edition 2019-02
Document ID rel8583

Contents
2maxon BIKEDRIVE | User Manual | rel8583
1Operation 3
1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Functional Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Driving Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5.1 PowerGrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.5.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.6 Before the Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.7 Riding the Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.7.1 Power Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.7.2 Motor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.7.3 Battery Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 After the Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2Maintenance 13
2.1 Care & Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.1 After each Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2 Storage of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4 Replacing the rear Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.5 Cleaning the PowerGrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.6 Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3TechnicalData 35
Index 43
WARNING!
RIDING AN ELECTRIC BIKE IS DANGEROUS!
ALWAYS USE EXTREME CAUTION WHEN USING THIS PRODUCT. MISUSE
OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY OR DEATH. ONLY
USE THIS PRODUCT IF YOU ARE IN GOOD PHYSICAL HEALTH. NEVER ACT
IN A CARELESS MANNER WHEN USING THIS PRODUCT. YOU ARE
RESPONSIBLE FOR YOUR SAFETY AND THE SAFETY OF OTHERS AROUND
YOU WHEN USING THIS PRODUCT!
C
on
t
en
t
s

Operation
Components
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SYMBOLS USED
1OPERATION
1.1 Components
Figure 1 maxon BIKEDRIVE — Components
Indicates a potentially hazardous situation. Ignoring can cause serious
injury!
Indicates a possibly dangerous situation or draws attention to an unsafe
practice. Ignoring can cause injury or damage to components!
Indicates an important aspect. Ignoring can cause damage to components!
In illustrations, only the “eye” will be displayed.
Indicates an important aspect or gives important additional information.

Operation
Legal Regulations
4maxon BIKEDRIVE | User Manual | rel8583
1.2 Legal Regulations
Legal regulations
Inquire about the current legal requirements in your country or in your area before
putting your bike into operation.
Equipped with the BIKEDRIVE, the bike is a vehicle with motorized assistance.
Depending on the country, the vehicle is called E-Bike, Pedelec (Pedal Electric
Cycle), electric or motor-assisted bicycle, electro moped, autocycle, or similar,
and is subject to appropriate legal regulations.
Federal, State, and in some cases, city laws regulate aspects, such as, traffic
rules, permitted speed, type approval and homologation, license plate, prove of
roadworthiness/road suitability before an official body, compulsory insurance,
driving license, required equipment (for example, lighting, acoustic warning
device, and specific brakes), etc.
1.3 Functional Principle
From a
standing
start in
action!
Motorized assistance of the BIKEDRIVE commences as soon as you start pedal-
ing while having selected a support level. The motor develops torque according
to the selected support level and the driven speed.
You can switch off and re-activate the motorized assistance at any time. With-
out pedaling, you can use the motor as pushing aid.
1.4 Driving Modes
Zero Motorized assistance is deactivated. You may switch to «Zero» at any time and
continue “normal cycling”. Thereby, the BIKEDRIVE behaves as if completely
switched off. It runs in internal freewheel and you will not even notice that it is
there.
Power1
Power2
Power3
You will be motor-assisted while pedaling. The torque applied by the drive will
be determined by the support level you have selected with the PowerGrip and
the driven speed.
Boost While pedaling in the highest support level «Power3», you can continue turning
the PowerGrip to get extra short-term performance and torque.
Pushing aid If you activate «Boost» without pedaling, the motor will support you while push-
ing the bike.

Operation
Handling
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1.5 Handling
A Word on
Safety
The BIKEDRIVE is extremely powerful! It possesses an extraordinarily high
degree of dynamics that will most likely surprise you at the beginning and it will
require some time to get used to.
Take it easy to start with and use caution on your first rides!
1.5.1 PowerGrip
Selecting the
driving mode
By rotating the PowerGrip you select the driving mode and, thereby, the degree
of motorized assistance (“Driving Mode” on page 7). You select the level using
four snap-in and one non-latching positions.
Each change of the selected support level is temporarily displayed by LEDs 1…5.
Following a support level change and while riding, the LEDs will show the
remaining battery level (“Charging Level” on page 8). The system status is
continuously displayed with LED A (“Status Indicator” on page 8).
Figure 2 PowerGrip
WARNING
Risk of injury
The BIKEDRIVE it extremely powerful and highly dynamic. Lack of habituation
to the high performance, handling, or operation can lead to serious injury!
• Be aware that the BIKEDRIVE will fundamentally change the driving behavior
of your bike — particularly in respect to aspects, such as, weight, weight distri-
bution, center of gravity, braking distance, braking response!
• Use extra caution during the “acclimatization phase” and select a low degree
of motorized assistance!
• Be aware that a changed setting at the PowerGrip will have an immediate
effect on the drive system, on speed, and on handling!

Operation
Handling
6maxon BIKEDRIVE | User Manual | rel8583
1.5.2 Battery
On the battery you will find the main switch, a lock, and displays for battery
charge and battery system status (page 8).
Figure 3 Battery BX360 ONE / BX500 ONE (left side)
Figure 4 Battery BX360 ONE / BX500 ONE (right side)
Power up To power up the battery, press the main switch. During startup, all LEDs light
up. After successful initialization, the LEDs will go out for a moment. Subse-
quently, the charging level of the battery will be temporarily displayed before
the LED display will go off.
To display the battery charge level at anytime during your ride, press the main
switch.
Turn off To turn off the battery, press the main switch until the LED display goes off. This
takes about 3 seconds. This takes about 3 seconds.

Operation
Handling
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1.5.3 Displays
The PowerGrip features an LED display that will inform you about the currently
selected driving mode, the charging level of the battery, and the status of the
system. A second LED display for the charging level is located at the battery.
Dimming To prevent glare, the brightness of the PowerGrip’s LED display will automati-
cally adapt to the ambient light.
Identification of the PowerGrip
During initialization of the system, the type of PowerGrip is displayed via the
LEDs.
Driving Mode
The selected support level is briefly displayed with each change. Thereafter, the
battery charge level is indicated.
Identification
dotX25 dotX33 dotXUrban
Zero
Neutral position — motorized assistance is turned off.
The PowerGrip engages in this position.
Power1 Turning towards you from the neutral position «Zero»
switches consecutively into levels «Power1», «Power2»,
and «Power3».
Turning away from you switches consecutively one level
back.
The PowerGrip engages in the selected position.
Power2
Power3
Boost
Turning towards you from the level «Power3» switches
to level «Boost».
The PowerGrip does not engage in this position and
bounces back to level «Power3» when released.

Operation
Before the Ride
8maxon BIKEDRIVE | User Manual | rel8583
Charging Level
The remaining relative capacity of the battery is displayed in 20% steps.
Status Indicator
The operating condition and system temperature (in color graduation) is dis-
played.
The meaning, for example, is lights up in blue, flashes in red.
1.6 Before the Ride
IMPORTANT—Power-up procedure
During power-up procedure, the BIKEDRIVE will perform a self test and initialization.
Moving the bike contrary to the driving direction during this process can lead to mal-
function. Therefore, while power-up procedure is in process,…
• do not rotate the rear wheel backwards (contrary to the driving direction),
• do not block the rear wheel,
• do not apply brakes!
1) Make sure that the battery is sufficiently charged for your planned
tour.
2) Make sure that the battery is turned off (page 6).
3) Slide battery into battery rail, let it click into place, and lock it. Remove
key.
4) Turn PowerGrip in neutral position «Zero».
5) Turn on main switch on battery.
6) After successful initialization you are good to go. Bear in mind the
safety notes on page 5!
Charging
level
100…80% 80…60% 60…40% 40…20% 20…0%
Operating
condition System
off
System
error
Master
halted
System
temperature
cold normal heated warm
“Riding the Bike” on
page 9

Operation
Riding the Bike
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1.7 Riding the Bike
1.7.1 Power Limitation
In order to achieve a largest possible range, the motor power will be limited in
certain support levels (Table 1).
Table 1 Power limitation (factory setting)
1.7.2 Motor Power
While riding, various system parameters are continuously monitored. As the
motor or battery temperature reaches a certain limit, the system automatically
limits the maximum output torque. You may of course continue cycling but you
must make do with reduced motorized assistance. The actual system tempera-
ture will be displayed via the PowerGrip’s multicolor LED A (“Status Indicator”
on page 8).
PowerGrip Support
Level
Torque
[Nm]
Limitation
[W]
dotX25
Power1 10 80
Power2 20 180
Power3 30 —
Boost 50 —
dotX33
Power1 10 180
Power2 20 —
Power3 30 —
Boost 50 —
dotXUrban
Power1 7.5 180
Power2 15 —
Power3 22.5 —
Boost 39 —
System
heated
Cause: This is no reason for concern! You are using the BIKEDRIVE for what it
is made for; motorized propulsion while pedaling.
What happens now? Just keep on going!
Depending on driving behavior, topography or usage of «Boost», heating of
motor or battery will possibly further increase and will, eventually, lead to the
status indication «System warm».

Operation
Riding the Bike
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1.7.3 Battery Capacity
Among other factors, the operating range per battery charge also depends on
the following influencing factors.
How to get
the most out
of a battery
charge
• Gross weight and rolling friction: For example, additionally carried
weight, trailer, low tire pressure, grazing brakes, worn components,
headwind.
• Topography
• Ambient temperature: By principle, the battery can only deliver its
maximum capacity within given temperature limits (Table 6 on
page 38).
• Support level/start-up/acceleration/changing gears: The more you
make use of motorized assistance (thus especially at start-up, during
acceleration, and when climbing a hill), the less your distance and
operating range will be.
Use the gears as with a “normal” bike. Thereby, shift early into a lower
gear when climbing a hill.
Running
empty
You may fully discharge the battery. The internal controller ensures that the
battery does not suffer damage. However, the battery should be recharged
soon thereafter, at the latest within a week.
Shutdown The BIKEDRIVE switches off completely after approximately 15 minutes without
power output. To recommence the motorized ride, restart the BIKEDRIVE
(“Before the Ride” on page 8).
System warm
Cause: You have pushed the BIKEDRIVE to the maximal permitted
temperature of the motor or the battery.
What happens now? Just keep on going!
The motor will automatically regulate to the highest possible torque output
without exceeding the maximum permitted temperature of the motor or the
battery.
The more you relieve the motor, the sooner you can expect to return to reach
full torque. Thereby, cooling of the battery takes significantly longer than the
cooling of the motor.

Operation
After the Ride
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1.8 After the Ride
If you take a
break:
Always turn the BIKEDRIVE completely off whenever you are not sitting on the
bike.
1) Turn the PowerGrip in neutral position «Zero».
2) Turn the BIKEDRIVE off.
After the fun
is before the
fun!
Perform the following steps for your BIKEDRIVE to deliver riding pleasure for
many years:
1) Turn the PowerGrip in neutral position «Zero».
2) Turn the BIKEDRIVE off.
3) Clean the bike (page 13).
4) Remove the battery.
5) Remove moisture from motor, PowerGrip, battery, battery rail, and
cables, if any.
6) Charge the battery (page 13)
7) Observe the instructions on battery storage (page 15).
Prepare for
transport:
1) Remove the battery and cover the battery rail to protect it from dirt
and humidity.
2) Protect the bike from dirt, dust, rain, snow, salt water, spray water. If
necessary, use transport bag or cover with tarpaulin.
3) Observe the bike manufacturer’s instructions if you intend to remove
the front and/or rear wheel for transport.
4) Observe the following remark on air transportation if you intend to
take your bike along on a flight.
Transport by Air
According to the International Air Transport Association (IATA), lithium batteries with
a capacity exceeding 100 Wh are considered as hazardous goods subject to appro-
priate conditions for air transport. Carriage on board passenger aircraft is not per-
mitted.
Note that all BIKEDRIVE batteries have a capacity of more than 100 Wh.
Check with your airline or your travel agent on means of transportation before
scheduling a flight.

Operation
After the Ride
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Maintenance
Care & Maintenance
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2MAINTENANCE
The BIKEDRIVE is designed for a demanding off-road use and is extremely
sturdy. Nevertheless, please contact your authorized BIKEDRIVE dealer if any
malfunction should occur.
Please note: You are not entitled to perform any repair on the BIKEDRIVE. It does
not contain any user-serviceable parts.
After appropriate instruction by the specialized dealer you are permitted to
carry out the following described cleaning, inspection, and maintenance work.
Thereby, keep strictly to the instructions and be aware: A manipulation of the
bike that is equipped with a BIKEDRIVE carries a certain danger of getting
injured. Careless or irresponsible behavior or failure to follow the precaution-
ary measures can cause the drive to start.
2.1 Care & Maintenance
2.1.1 After each Ride
Cleaning with Water
Do not expose motor and battery to direct water spray!
1) Clean bike: Remove soiling using a damp rag.
2) Remove moisture: Rub dry motor, battery, cables, and plug connec-
tors with a soft cloth.
WARNING
Risk of injury
Work on the bike can lead to serious injury!
Turn off the BIKEDRIVE and remove the battery before you commence with any
work, such as cleaning, maintenance, or troubleshooting!
WARNING
Risk of injury
You must no longer use visibly damaged batteries. Continued use can lead to
serious injury!
• Remove the damaged battery from the battery rail!
• Do not connect the damaged battery to the battery charger!
• Discard the damaged battery in no case with normal household waste but
only to the appropriate official collection site or via your specialized dealer!

Maintenance
Care & Maintenance
14 maxon BIKEDRIVE | User Manual | rel8583
3) Check for damage: Check motor, battery, cables, and plug connectors
for external damage. Let your authorized BIKEDRIVE dealer replace
any damaged part immediately.
4) Check PowerGrip for ease of movement: It must automatically
bounce back when «Boost» is released. If this is not the case, you have
to dismount and let clean the PowerGrip (page 22).
5) Charge battery: Choose a cool place to charge the battery. For infor-
mation on charging temperature and duration see Table 6 on
page 38.
a) Connect battery charger with battery.
b) Connect battery charger to power outlet (100…240 VAC, 50…60 Hz)
and switch on.
c) Switch on battery. The charging process commences. Also observe
the following note «Remarks on the Charging Process».
d) Disconnect battery from battery charger.
e) Disconnect battery charger from power plug.
Remarks on the Charging Process
• The progress of the charging process is indicated by the battery LEDs. Thereby,
the currently level being charged flashes, the already charged levels light up
(
 page 33).
• The battery may warm up during charging. If the specified charging temperature
range is exceeded, this is indicated by the battery charge indicator and charging
will be interrupted. After a cooling phase, charging will resume automatically. The
charging time can be prolonged.
• After reaching the full battery charge, the battery automatically shuts off. The
LEDs on the battery go out.
WARNING
Risk of injury
Improper charging of the battery can lead to serious injuries!
• Carry out charging only outdoors or in rooms equipped with fire detectors.
Use a fireproof pad and keep sufficient distance to flammable materials!
• Use only an original BIKEDRIVE battery charger!
• Protect the battery, battery charger, and plug connectors from contact with
humidity (water, dew, cleaning agents, etc.) and observe the permitted envi-
ronmental conditions!
• Do not carry out any manipulation, cleaning, or maintenance on the bike
while charging is ongoing!
• Oversee the charging process!
• In the event of fire:
• – Do not inhale combustion gases!
• – Call fire department!
• – Do not extinguish with water – use fire blanket!

Maintenance
Care & Maintenance
maxon BIKEDRIVE | User Manual | rel8583 15
• The amber battery charger LED indicates that the battery charger is connected to
the battery. The LED lights up for the entire duration and after completion of the
charging process.
• The battery charger’s fan may automatically switch on and off during charging.
• If no battery is connected to the charger, the red battery charger LED lights up.
6) Store battery in a cool dry place. For example, do not let the battery
in your car when it is exposed to direct sunlight since it can get
extremely hot in a very short time! Also, observe the permitted envi-
ronmental conditions (page 38)!
2.1.2 Storage of the Battery
Store the battery in a cool, dry place. For information on the maximum permit-
ted storage temperature see Table 6 on page 38.
Long-term
storage
If you are not using the battery for extended periods, store it at approximately
60% of its capacity. A permanently higher charge will accelerate the principle-
related natural aging of the battery.
2.1.3 Periodic Inspection
In addition to the maintenance specified by the bike manufacturer, you or your
authorized BIKEDRIVE dealer must perform the following inspections.
Table 2 Maintenance plan
When? What?
After heavy use Brakes: Check wear on brake discs and brake pads,
replace if necessary
Every 200 km
or
at least annually
•Rear wheel: Check on specified spoke tension
•Quick-release axle: Check for firm fit
•Screw connections: Check for firm fit
•Plug connections: Check for firm fit
Every 1000 km
or
at least annually
Battery rail: Check for firm fit
When not in use or
for storage:
Every 6 months
Battery: Charge battery to approximately 60% (this
corresponds to approximately 3 of 5 battery LEDs).
Periodically check the charge and recharge to 60%, if
necessary.

Maintenance
Care & Maintenance
16 maxon BIKEDRIVE | User Manual | rel8583
2.1.4 Replacing the rear Brake Disc
BIKEDRIVE axles are available in two designs; with quick-release lever or hexa-
gon socket (Figure 5). For better legibility, in the further course only the quick-
release version (A) will be shown.
Figure 5 Axle versions
2.1.4.1 Dismantling
IMPORTANT
During disassembly, exposed parts can easily be damaged. Exercise caution.
Remove
cover
1) Disconnect motor plug from
Power Cable.
2) Dismantle rear wheel.
3) Loosen and remove screws
(A).
4) Carefully pull off cover (B).

Maintenance
Care & Maintenance
maxon BIKEDRIVE | User Manual | rel8583 17
Fold down
cable
Loosen
set screw
5) Carefully fold down cable (C)
by approx. 90°.
6) Loosen set screw (D) about 3
turns (do not remove!).
Remove
torque lever
IMPORTANT
Do not damage cable.
7) Carefully pull off torque lever
(E) in axial direction from
hub by slightly weighing back
and forth. Put over cable and
plug and remove.
Remove
brake disc
8) Loosen and remove screws
(H).
9) Remove spacer plate (G).
10) Carefully pull off brake disc.

Maintenance
Care & Maintenance
18 maxon BIKEDRIVE | User Manual | rel8583
2.1.4.2 Reassembly
IMPORTANT
• During reassembly, parts can easily be damaged. Exercise caution.
• Use only one-piece, flat steel brake discs.
• To attach the brake disc, use only the maxon «Brake Screw Kit TX25», the
originally used, or as to below specified screws.
• The screws must not axially touch the bottom of the tap. Wrong or too long
screws lead to permanent damage of the motor.
Use «Brake
Screw Kit
TX25»
or
check
dimensions
RECOMMENDATION
Use maxon’s «Brake Screw Kit
TX25» (upper illustration).
If you decide not to use the
maxon screw kit:
Make sure that fastening screws
and washers correspond with
the indicated dimensions
(lower illustration)!
Mount
brake disc
1) Check brake disc and hub for
cleanness, clean if necessary.
2) Observe specified brake
disc’s sense of rotation.
3) Slide brake disc (F) on hub,
align radially.
4) Mount spacer plate (G).
5) Mount screws (H) from
«Brake Screw Kit TX25» (for
others, apply medium
strength threadlocker first),
lightly tighten by hand.
6) Turn brake disc against direc-
tion of travel until it strikes
against screws.
7) Tighten screws crosswise
(torque 7 Nm).

Maintenance
Care & Maintenance
maxon BIKEDRIVE | User Manual | rel8583 19
Mount
torque lever
8) Align cable cutouts of torque
lever (E) and hub.
IMPORTANT
Do not damage cable.
9) Carefully put torque lever in
axial direction over cable and
plug, slide onto hub.
Mount
set screw
Fold up cable
10) Radially align torque lever.
11) Carefully tighten set screw
(D). Do not apply thread-
locker!
12) Carefully fold up cable (C) by
approx. 90° and insert into
groove.
Mount cover
13) Place cover (B) on torque
lever and align.
IMPORTANT
The cable must entirely rest in
the groove. It must not protrude
nor be pinched in the separating
pane.
14) Mount screws (A) and lightly
tighten.
15) Check cover for correct fit.
16) Tighten screws crosswise
until parts fully contact.

Maintenance
Care & Maintenance
20 maxon BIKEDRIVE | User Manual | rel8583
Install rear
wheel
17) Rotate rear wheel until
torque lever points in direc-
tion of travel.
IMPORTANT
Do not damage cable.
18) Carefully position rear wheel
in dropout ans mount as fol-
lows:
QR
• Lead axle from left through
the motor’s hollow shaft.
• Align rear wheel, hold tension
nut, and slightly tighten axle.
E-Thru threadless
• Insert tension nut in right
dropout.
• Insert axle from left through
the motor’s hollow shaft.
• Align rear wheel, slightly
tighten axle.
E-Thru / Flush / Maxle / X-12
• Screw tension nut in right
dropout, tighten by hand until
stop.
• Insert axle from left through
the motor’s hollow shaft.
• Align rear wheel, slightly
tighten axle.
Mount stop-
per sleeve
19) Check condition of scratch
guard (illustration, circle),
replace if necessary.
20) Turn torque lever against
direction of travel until
torque lever strikes against
frame from below.
21) Tighten axle.