Mondraker DUSTY 2023 User manual

Rev. 01
MANUALS & DOCUMENTS
DUSTY 2023 / EN

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DUSTY 2023
Manuals & Documents
Not keeping to the indications or following unsafe practices may result in serious injuries or even death.
The tasks involve technical diculty and if they are badly developed, they could damage your bicycle or result in
a void warranty.
SAFETY AND GENERAL INSTRUCTIONS
CONSIDERATIONS
CLEANING & CARE
Please, be aware that the following 3 icons may appear in this technical guide. Each one indicates to take the
following precautions:
• Using non-original spare parts may result in damage, malfunctions and accidents which may lead to severe
consequences.
• Please note that to perform some of the steps described in this manual, skills beyond the average bicycle
user are required. In the event of not being qualified to follow any of these steps, please take your bicycle to
a Mondraker authorized technical service for maintenance and replacement of its components. The incorrect
installation of spare parts can result in malfunctions, accidents, injuries, and warranty void.
• Once the pieces are disassembled, it is recommended to clean, grease, and put threadlocker (if necessary) on
the components which are going to be re-used.
Not keeping to the indications or following unsafe practices may result in light injuries. The tasks involve
technical diculty and if they are badly developed, they could damage your bicycle or result in a void warranty.
Information which is essential for a proper execution of the task and therefore, avoid any possible damage to
your bicycle or loosing the warranty, but does not involve any risk for the person.
WARNING!
CAUTION
INFORMATION

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Manuals & Documents
GEOMETRY
SEAT POST INSERTION DEPTH
O
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Seat Tube Length
Top Tube Length
Bottom Braket Drop
Bottom Braket Height
Chainstay Length
Seat Tube Angle, Actual
Seat Tube Angle, Eective
Head Tube Angle
Fork Oset
Wheelbase
Head Tube Length
Reach
Stack
Stem Length
Fork Height
440 mm
550 mm
70 mm
286 mm
425 mm
74º
74º
70º
45 mm
1034 mm
125 mm
393 mm
548 mm
70 mm
420 mm
500 mm
595 mm
70 mm
286 mm
425 mm
74º
74º
70º
45 mm
1082 mm
175 mm
424 mm
595 mm
80 mm
420 mm
530 mm
620 mm
70 mm
286 mm
425 mm
74º
74º
70º
45 mm
1110 mm
210 mm
440 mm
628 mm
90 mm
420 mm
460 mm
570 mm
70 mm
286 mm
425 mm
74º
74º
70º
45 mm
1056 mm
150 mm
405 mm
576 mm
70 mm
420 mm
SIZE S M L XL
XL
L
M
S
100
100
100
100
270
250
230
190
FRAME SIZE MAX. (MM)MIN. (MM)

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Manuals & Documents
REAR WHEEL ASSEMBLY / DISASSEMBLY INSTALLATION GUIDE
Before wheel assembly or disassembly
loose the hanger so it can pivot.
LOOSE
When attaching the wheel to the frame,
please take great precaution to avoid
damaging the motor connection pins.

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Manuals & Documents
BOTTOM BRACKET INSTALLATION GUIDE
NO GAP STEM
Align and insert bottom bracket non drive
side first. The alignment must be between
the bottom bracket mark and the rear
wheel axel. This process requires special
tools, please refer to Mahle for further
details.
When assembling the stem, tight the
top screws first so there is no gap on
the upper side.
5-6 Nm
ALIGN
± 5º MAX TOLERANCE

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INTERNAL CABLE ROUTING HEADSET INSTALLATION GUIDE
HEADSET ASSEMBLY
Follow routing order to avoid cable crossing.
REAR BRAKE FRONT BRAKE
DERAILLEUR
E-SHIFTER
E-SHIFTER
1
1
2
3
4
5
6
7
HS BEARINGS + CR DUSTY 23
HS BEARING SEALS 23
DUSTY STEM 70MM 23
DUSTY STEM 80MM 23
DUSTY STEM 90MM 23
DUSTY HS SPACERS KIT + COVER 23
DUSTY DISPLAY MOUNT 23
020.23990
020.23991
020.23992
020.23993
020.23994
020.23995
020.23996
Kit No. DESCRIPTION PART NUMBER
2
2
6
6
6
4
5
3
7
1

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SPARE PARTS
Grease
Threadlocker
Grease + Threadlocker
* Apply grease to the shaft, and locker to the threads.
16
23
202
17
23
18
23
112 11
4
21
5
2
3
6
14
22
4
4
19
15
13
9 10
87
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
FRAME
BATTERY BOLT + WASHER M5x16L
BATTERY COVER
BOLT M3x8L M-S
FRAME RUBBER PROTECTOR
CHAIN STAY RUBBER PROTECTOR
HANGER NUT
EGRAVEL HANGER
EGRAVEL LEFT ADAPTOR MOTOR
MOTOR ADAPTOR
SEAT CLAMP
SEAT CLAMP BOLT
REAR AXLE 142x12
BRAZE ON
STEEL HEX DRIVE FLAT HEAD SCREW M4x8L-MS
BLACK FORK
FRONT AXLE
CONTROLER BOLT M3x10L-SP-SB
MOTOR HUB PORT BOLT M3x6L P-S
TOP INTERNAL BATTERY SPACER
BOTTOM INTERNAL BATTERY SPACER
BRAZE ON COVER
FORK/TOP TUBE RIVET PLUG
099.23011
SET 6
SET 3 / 6 / 2
099.23006
099.23007
SET 1
SET 1
SET 2
SET 3
SET 4
SET 4
099.23009
SET 5
SET 5
099.23010
099.23008
099.23042
099.23043
099.23044
099.23045
4Nm
1 Nm
4Nm
5Nm
12 Nm
2Nm
12 Nm
1 Nm
1 Nm
1
2
1
9
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
8
ITEM No. Q T Y. PART NUMBER TORQUEDESCRIPTION

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SPARE PARTS
FAQs
SET 2
LEFT DROPOUT
SET 3
LEFT DRIVE ADAPTOR
SET 1
HANGER M076 + NUT
099.00066
099.23001
099.23002
099.23003
099.23004
099.23005
SET 1: HANGER M076 + NUT
SET 2: LEFT DROPOUT
SET 3: LEFT DRIVE ADAPTOR
SET 4: SEAT CLAMP
SET 5: FRONT DERAILLEUR BRAZE ON
SET 6: BATTERY COVER
HANGER (x1) / HANGER NUT (x1)
EGRAVEL LEFT ADAPTOR MOTOR (x1) / SCREW BOLT (x3)
MOTOR ADAPTOR (x1) / SCREW BOLT (x2)
SEAT CLAMP (x1) / SCREW BOLT (x1)
BRAZE ON (x1) / SCREW BOLT (x2)
BATTERY COVER (x1) / SCREW BOLT (x2)
PART NUMBER DESCRIPTION COMPONENTS
IS IT POSSIBLE TO CHANGE THE DRIVETRAIN ON THE DUSTY?
Dusty have been designed around a 1X 40T ring crankset. You can either alter the ring tooth size, go 2X Wide
standard or change the cassette. The X20 system features a BB386 bottom bracket with integrated torque sensor
and cadence meter. To remove it, a special tool supplied by Mahle is required. Q-Factor is 150mm and chain line is
47,5mm.
IS IT POSSIBLE TO ALTER THE BAR HEIGHT?
The handlebar height on the three Dusty models has 10mm of adjustment, modifying the position of the steerer
tube spacers. It is important to note that the stem uses a specific shim for this model and the correct cable rou-
ting, so it will not be possible to use a dierent stem model than the ones we spec as standard equipment on the
bikes.
WHICH ARE THE HANDLEBAR WIDTHS BEING USED?
Dusty is equipped with 440mm width handlebars in sizes S and M and 460mm in sizes L and XL. The “flare” or
handlebar drop-out is 18mm, making it an ideal option on our Dusty for a comfortable position while maintai-
ning good contact with the brake levers.
IS IT POSSIBLE TO CHANGE THE POSITION OF THE HANDLEBAR-MOUNTED E-SHIFTERS ON MY DUSTY?
Yes, the e-Shifters remote controls located on both sides of the handlebars that allow you to change the support
modes of the X20 motor can be repositioned. In fact, Mondraker does not assemble them as a standard equi-
pment on the bike so that the owner himself, at the dealer floor, can fit them where he considers convenient or
deems appropriate. For the same reason, the handlebar tape is not fitted either.
CAN I INSTALL A DROPPER POST?
Yes, you can install a 27.2mm diameter dropper post. In fact, Dusty XR model is specced with a SRAM Reverb XPLR
AXS 27.2 x 400mm dropper.

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FAQs
WHICH IS THE MAXIMUM TIRE WIDTH I CAN RUN ON THE DUSTY?
To guarantee the proper clearance on both fork and frame, maximum recommended width should not exceed
700x47c.
IS IT POSSIBLE TO INSTALL A SUSPENSION FORK ON DUSTY?
Sure you can install a suspension fork, gravel specific with a maximum travel of 50mm. In fact, Dusty XR model is
specced with a RockShox Rudy Ultimate XPLR with 40mm of travel.
WOULD IT BE POSSIBLE TO ADD A RANGE EXTENDER TO RIDE LONGER?
At Mondraker we oer an Range Extender e185 from Mahle “water-bottle” mount style which oers 171Wh. It
weighs 1.1 kilogram and, additionally, you will enjoy greater 50% longer range compared to the internal 350Wh
battery. It features 21.700 cells, takes 1h to recharge it up to 80% (2h for completely charged).
IS IT POSSIBLE TO DISASSEMBLE THE INTERNAL BATTERY?
Dusty models have been designed with the best possible performance and design integration in mind so internal
350Wh battery is not removable. To charge the Dusty you have to plug it directly to a wall socket.
WHICH IS THE MAXIMUM ASSISTANCE I CAN GET FROM THE DUSTY MOTOR?
Dusty models feature the same frame and the same Mahle’s latest generation X20 hub motor. The weight of the
motor is only 1.4 kilograms and delivers 23Nm to the wheel, comparable to 55Nm on a mid-motor.
IS IT POSSIBLE TO CUSTOMIZE THE ASSISTANCE MODES ON THE DUSTY?
The X20 system on the Dusty features three assistance modes for dedicated gravel riding which are driven by the
Watts On Demand concept. The assistance provided by the motor in each of the modes is proportional to the phy-
sical eort you make. Mode 1 oers a level of assistance up to 25% greater than our physical eort. Mode 2 oers
up to 50% more and mode 3 ranges from 70% to 200% more power than the eort we apply when pedalling. It
is a level of support that feels very natural, not intrusive, providing just the right amount of power in each of the
modes, optimizing and maximizing battery life and range. The three modes are configurable and can individua-
lly modify the maximum power, acceleration and initial support / reactivity in each level of assistance. Through
the Mahle MySmartbike app -available for both iOS and Android devices- you can find all the data related to your
experience riding the Dusty as well as access to the customization of the assistance modes.
WHICH INFORMATION DOES THE DUSTY’S DISPLAY OFFER?
Mahle’s 2.1” sized Pulsar One display features wireless connectivity and allows you to visualize at a glance
information on screen such as main -and range extender if connected- battery charge status, assistance level,
riding data such as current speed, average speed, trip and total distance, trip time, cadence, power sensor (real
time data on watts of power output) or heart rate (via ANT+ sensors). It works with a CR2032 battery and uses a
mounting bracket compatible with Garmin devices. Any GPS device with Bluetooth/ANT+ connectivity with eBike
protocol is likewise capable of displaying the system data on screen.
IS IT POSSIBLE TO UPDATE THE SYSTEM FIRMWARE?
Sure. This operation is done through the battery charger that will update the system simultaneously while char-
ging the bike. To do so, we will have to download the latest version of the firmware available from the PC/Mac to
the charger itself through the Micro-USB port and, once we connect the charging port on the bike itself to charge
the battery, the system will be updated.
I HAVE NOT BEEN RIDING FOR LONG AND NOW MY BIKE DOES NOT TURN ON, WHAT SHOULD I DO?
If you have not ridden the Dusty for more than 60 days, the bike automatically goes into sleep mode. Plug in the
charger and keep it plugged in for at least 1 hour to reactivate the motor and battery operation properly. If you
are sure that you are not going to ride the bike for a long time, keep in mind that in order to keep the battery
working at its best and extend its life, it is important to store it between 20 and 80 percent.

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FAQs
I’D LIKE TO KNOW MORE DETAILS ABOUT DUSTY’S X20 MOTOR, WHERE CAN I FIND MORE INFORMATION?
You can download the user manual following this link: https://mahle-smartbike.com/downloads/ and clicking on
X20 System User Manual.
IS IT POSSIBLE TO RIDE THE DUSTY WITH STANDARD NON-MOTOR POWERED OR EVEN 650B WHEELS?
A smaller 650 diameter wheel is technically compatible. Having a motor in the rear wheel would require the
wheel to be laced and this is an operation that is not convenient to be carried out by anyone other than an autho-
rized Mahle dealer, so we do not recommend it. The Dusty frame has exclusive dropouts for the Mahle X20 drive,
so it is not possible to use a standard wheel.
I KNOW THAT THE DUSTY CAN BE FITTED WITH RACKS, MUDGUARDS... BUT IS THERE A SPECIFIC CUSTOM TRAVEL
BAG CREATED FOR ITS VERY SPECIAL DESIGN?
For this purpose, at Mondraker we have created two models of bags from the brand Apidura that have been
customized for the Dusty’s design. One of them can be fitted on the front of the top tube and the other on the
inner front side of the main triangle. Both have an innovative design and are high quality. In addition, the Dusty
models have been designed for multidisciplinary use and can carry up to three water bottle cages on the front
triangle - down tube, seat tube and top tube - including two additional ones on both sides of the fork, as well as
mudguards, racks, etc.
HOW MUCH DOES THE DUSTY FRAME AND THE RIGID CARBON FORK WEIGH?
Dusty frame weighs 1,298 grams and the gravel-specific carbon fork weighs 579 grams.
WHICH IS THE MAXIMUM RECOMMENDED RIDER WEIGHT WITH EQUIPMENT DUSTY IS ABLE TO SUPPORT, IN
OTHER WORDS, THE SYSTEM WEIGHT (BIKE+RIDER+EQUIPMENT)?
System weight (Bike + rider + total equipment) weight limit is 120 kg.
WHICH SIZE SHOULD I BUY?
Sizes dier from one rider to other. Personal preferences are very unique and how you ride your bike is also im-
portant when choosing the correct size. This is a standard size chart you can use as a guideline.
S= 440mm seat tube 1.58 - 1.68
M= 460mm seat tube 1.67 - 1.76
L= 500mm seat tube 1.75 - 1.86
XL= 530mm seat tube 1.85 - 1.95

All information and pictures on this document is provided for information
purposes only and does not constitute a legal contract between Mondraker
and any person or entity. Specifications, geometries or any other technical
information published is subject to change without prior notice.
© ® All trademarks and models are property of Blue Factory Team, S.L.U.
and are protected by current laws and applicable international agreements.