Maxon BIKEDRIVE User manual

maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 1-1
Operating Manual

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
1-2 mint | 2022-08 | 9473424-01
1 CONTENT AND SYMBOLS 5
1.1 Currentness of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 DRIVE SYSTEM 7
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 SYSTEM OVERVIEW 9
3.1 Components / scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.2 POWERTAB / Battery SOC indicator . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.3 Battery BX250I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.4 Range Extender BX250E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.5 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.6 Charging socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.7 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.8 Remote switch for mountain bikes. . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.9 Remote switches for racing and gravel bikes . . . . . . . . . . . . . . . . . 16
3.2.10 Light module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.11 Installation of non BIKEDRIVE AIR accessories . . . . . . . . . . . . . . . 17
4 COMMISSIONING AND OPERATION 19
4.1 POWERTAB function overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Selecting the support level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Individually configuring the support levels with the Connect app . . 20
4.1.3 POWERTAB energy supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.4 Meanings of the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Installing and removing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Safety alerts and warning information for the battery . . . . . . . . . . . . . . 22
4.5 Using the charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.1 Connecting the charger to the power grid . . . . . . . . . . . . . . . . . . . . 25
4.5.2 Charging process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.3 Maintenance and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7.1 Installing the Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TABLE OF CONTENTS

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 1-3
4.7.2 Changing the Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.3 Meanings of the LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.8 Safety alerts and warning information for the Range Extender . . . . . . 28
5 MAINTENANCE 31
5.1 After an accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 CLEANING AND CARE 33
7 TRANSPORT 35
8 LIABILITY FOR MATERIAL DEFECTS 37
9 DISPOSAL 39
9.1 General information / disposal instructions . . . . . . . . . . . . . . . . . . . . . . 39
9.1.1 Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.1 Second use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIST OF FIGURES 41
LIST OF TABLES 43

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
1-4 mint | 2022-08 | 9473424-01
• • p a g e i n t e n t i o n a l l y l e f t b l a n k • •

Content and symbols
Currentness of the operating manual
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 2-5
1 CONTENT AND SYMBOLS
This operating manual only contains specific information about your
BIKEDRIVE AIR and should be used in combination with the operating manual of
the bike (Owner’s Manual). Please read the Owner’s Manual in its entirety before
using your BIKEDRIVE AIR. If you do not have a printed version of the Owner’s
Manual, it can be downloaded from the website of the dealer, or contact your local
dealer.
Additionally, this operating manual contains important information that increases the
safety, makes it possible to achieve a long service life for the BIKEDRIVE AIR, and
increases the enjoyment of riding with the e-bike. Disregarding the content of the
operating manual can cause damage to the vehicle and personal injuries.
Make sure that your authorized dealer provides you with all documents that belong
to the product. If certain information in this manual contradicts the product informa-
tion of a component manufacturer, please contact your local dealer.
The following symbols are used in the operating manual:
Indicates a potentially hazardous situation. Noncompliance can lead to
severe injuries.
Indicates a possibly hazardous situation or an unsafe practice.
Noncompliance can lead to injuries or damage to components.
Indicates an important aspect. Noncompliance can lead to damage to
components.
1.1 Currentness of the operating manual
The operating manual of the BIKEDDRIVE AIR is continuously checked to
ensure that it is up to date. The manual at hand reflects the knowledge
available at the time of printing. We recommend visiting our website at
maxonbikedrive.com/de/service to inform yourself about any changes. There
you can also find the current version of the operating manual as a PDF.
Safety alerts:
• Read this operating manual prior to use.
• Store the operating manual for future use.
• Closely read the operating manual for the optional components used.

Content and symbols
Currentness of the operating manual
maxon BIKEDRIVE AIR Operating Manual
2-6 mint | 2022-08 | 9473424-01
Never open the electric component of the BIKEDRIVE AIR yourself. Maintenance
must be performed by a specialist. Opening components automatically voids the
warranty.
Modifying the components or using components that are not intended for the
BIKEDRIVE AIR is not permitted and can critically affect the safety. Any
modifications or use of third-party components voids the warranty.
After a long ride, the BIKEDRIVE MX AIR drive unit can heat up significantly. This
poses risk of burns.

Drive system
Intended use
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 3-7
2 DRIVE SYSTEM
Congratulations on your purchase of the BIKEDRIVE AIR drive system. You have
chosen a drive system with the latest technology.
The bike equipped with the BIKEDRIVE AIR drive system has been developed for
the current electric bike market. The support is adjusted by means of a controller
that evaluates the data of three sensors (speed, cadence, and torque) and
regulates the motor depending on the selected level of support. Once a speed of 25
km/h is reached, no support is provided any more. However, you can ride faster
than 25 km/h using your own strength without electromotive support and without
additional resistance.
2.1 Intended use
Legal provisions
Inform yourself about the applicable statutory regulations in your country or at your
place of residence prior to commissioning your bike.
Your BIKEDRIVE AIR is intended for transporting one person on asphalt roads as
well as on paved and unpaved tracks. The permissible load (rider + accessories +
luggage) depends on the bike manufacturer, who is also responsible for providing
this information.
The BIKEDRIVE AIR is not intended for the following:
• Use in races / competitions
• Cleaning with a high-pressure water jet
• Transport on the outside of a car in rainy weather
• Charging the bike in an outdoor location where it is subject to moisture or
intense direct sunlight
The intended use can be limited by:
• The safety alerts in this operating manual
• The chapter “Commissioning and operation” in this operating manual
• The country-specific traffic regulations
• The country-specific regulations on registration for use in road traffic
Use of the BIKEDRIVE AIR is not recommended for the following user groups:
• Persons with restricted physical, sensory, or mental abilities
• Persons who are unable to safely operate the vehicle due to their size

Drive system
Intended use
maxon BIKEDRIVE AIR Operating Manual
3-8 mint | 2022-08 | 9473424-01
Modifications to the BIKEDRIVE AIR aimed at increasing the motor power or
the maximum support speed, pose a danger to your safety while riding. There
is risk of consequences under traffic, registration, insurance, regulatory, and
criminal law.
Rotating parts, such as wheels, crank arms, or pedals, can pull in clothing,
transported objects, and even body parts.
• Always wear close-fitting clothes, a helmet, and goggles.
• Wear shoes that have soles with good grip and that are appropriate for the ped-
als.
• Do not fasten any objects to your handlebar that could swing into the front wheel.
A bike equipped with BIKEDRIVE AIR accelerates faster than a conventional
bicycle. Always remember that other road users cannot know that you are
capable of such acceleration.
• First practice using your BIKEDRIVE AIR in a traffic-restricted zone before using
it in road traffic.
Active and passive light systems must be installed in accordance with the safety
regulations of the road traffic legislation of the corresponding country. The safety
equipment must be checked regularly and, if needed, repaired by a qualified
specialist.

System overview
Components / scope of delivery
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 4-9
3 SYSTEM OVERVIEW
3.1 Components / scope of delivery
Figure 4-1 BIKEDRIVE AIR | Components
Read all safety alerts and instructions.
Failure to comply with the safety alerts and instructions
can cause electric shock, fire, and/or severe injuries.
1Speed sensor 2Charging socket
3Drive unit 4Range Extender BX250E
5Battery BX250I 6Light module
7POWERTAB 8Remote switch
Charger (not shown)
78 5
12346

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-10 mint | 2022-08 | 9473424-01
Store all safety alerts and instructions for future reference.
The term “battery” used in this operating manual refers to all original
BIKEDRIVE AIR batteries.
•Do not get distracted by the display of the POWERTAB. If you do not
concentrate on the traffic only, you risk being involved in an accident.
• Read and observe the safety alerts and instructions in all operating manu-
als of the e-bike as well as in the operating manual of your
BIKEDRIVE AIR system.
3.2 System components
Depending on the configuration of your BIKEDRIVE AIR e-bike, some illustrations in
this operating manual might slightly differ from your actual bike.
3.2.1 Drive unit
• Do not remove and open the drive unit yourself. Only specialist personnel are
authorized to open it and it must be repaired with original spare parts exclusively.
Unauthorized opening of the system voids the warranty.
• Modification of the drive unit and installing other, unapproved products is not
permitted.
The drive unit consists of an efficient brushless maxon internal-rotor motor and a
low-noise performance planetary gearhead. The integrated electronics and sensors
ensure sensitive support in all riding situations. The patented, innovative freewheel
has no noticeable resistance – both when backpedaling as well as when riding
without electrical support.
Figure 4-2 BIKEDRIVE AIR | Drive unit