Royal Gazelle CityZen Speed Powertube User manual
Royal Gazelle
Repair and Maintenance Information
Service handbook / Technical manual
CityZen Speed Powertube
VIN numbers starting with *XRGA2xxxxxxxxxxxx*
Repair and Maintenance Information. Version 1.00, 02-07-2018
Introduction
This Repair Manual will help you to perform all the main maintenance and repair work
correctly and eciently. It should be consulted regularly by workshop personnel as an
addition to the practical and theoretical knowledge obtained in courses. It is a contribution
towards achieving a higher quality of service.
A new issue of this repair manual will be published if amendments or supplements are
needed. The latest issue date is shown in the header. All information in both text and
illustrations refer to speed pedelecs in standard condition or with genuine Gazelle
accessories installed.
In some cases, repair instructions are also issued in the form of Service Information. This
information will be incorporated into the next issue of the Repair and Maintenance Manual.
Royal Gazelle N.V.
After Sales
General table of contents
1. Maintenance and general instructions 3
2. General work units for city bikes and E-bikes 3
3. General work units for ATB/race/hybrid 5
4. Torque table 7
5. Fork maintenance guide 8
6. List of interchangeable parts 9
7. Wiring diagrams 12
8. Component & diagnostic information 13
9. Diagnostic fault-codes 13
10. Software versions 13
11. Special tools and equipment 13
12. Customer technical support 13
13. Royal Gazelle maintenance schedule 14
14. Royal Gazelle maintenance record 16
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Repair and Maintenance Information. Version 1.00, 02-07-2018
1. Maintenance and general instructions
For general information about service and maintenance, refer to the Gazelle User Manual.
Dutch: www.gazelle.nl/media/gene-cms/a/l/algemene_gebruiksaanwijzing_gazelle_fietsen.pdf
English: www.gazellebikes.co.uk/media/6314/user-manual-gazelle.pdf
2. General work units for city bikes and E-bikes
TYRES AVERAGE
MINUTES
BRAKES AVERAGE
MINUTES
LIGHTING AVERAGE
MINUTES
Repairing front or rear
inner tyre
15 Replacing or adjusting: Replacing:
Replacing of: Anchor plate front drum
brake
25 Front bulb 10
Inner or outer front
tyre – ordinary hub
15 Anchor plate rear drum
brake
35 Rear bulb 5
Inner or outer front
tyre – drum hub
20 Front or rear brake pads
rim brake or cantilever
10 Headlight 10
Inner or outer rear tyre 20 Mounting front and rear
cantilever brake
25 Taillight 15
Inner or outer rear tyre
– aluminum frame
30 Mounting front and rear
hydraulic brakes
90 Dynamo 10
BAGGAGE LOCKS Hub dynamo 30
Replacing rear carrier
(including light)
20 Replacing ring lock 15 Headlight cable
(around frame)
5
Mounting basket rack
on handlebar
20 Mounting carrier for
U-lock or cable lock
10 Headlight cable
(within handlebar)
15
Mounting carrier for
buggy or briefcase
15 ART ring lock 25 Tail light cable
(around frame)
10
Mounting cycle bags 10 REAR CARRIER STRAPS Light clamp on
head tube
15
COMPUTER Replacing straps (on
axis)
10 WHEELS
Mounting computer 10 MUDGUARDS Hub cleaning, adjusting,
replacing traces of wear:
Replacing computer
and holder (e-bike)
30 Replacing front
mudguard rod
15 Front wheel 25
FRAME Replacing rear
mudguard rods
20 Rear wheel - free-
wheel or brake hub
35
Replacing 180 Completely replacing
front mudguard
15 Rear wheel – gear
hub
60
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Repair and Maintenance Information. Version 1.00, 02-07-2018
TYRES AVERAGE
MINUTES
BRAKES AVERAGE
MINUTES
LIGHTING AVERAGE
MINUTES
COAT GUARD Completely replacing
rear mudguard
35 Wheel weaving:
Replacing (set) 5STAND Equal flange height 45
CABLES Replacing 10 Unequal flange
height
50
Replacing and adjusting: HANDLEBAR Eccentric 60
Front brake 10 Replacing and adjusting: Mounting and demounting:
Rear brake 15 Handlebar without
handle grip, brake grip
etc.
25 Front wheel 10
Gear hub 15 Handlebar with handle
grip, brake grip etc.
45 Rear wheel
(including chain
guard)
20
CHAIN Mounting brake grip 20 Rear wheel 10
Tightening and
lubricating
15 Headset 50 Wheel calibration
(e-bike)
15
Replacing, making fit,
tightening – gear hub
30 Front fork 60 Adjusting hub gear 10
Replacing, making fit,
tightening – derailleur
15 Handle grip 5CHILD SEAT
Replacing pinion or
cassette
25 CRANKSHAFT Mounting front child
seat
10
CHAIN GUARD Replacing: Mounting rear child
seat
20
Replacing: Left crank 15 ELECTRIC MOTOR
Varnished cloth 50 Right crank (incl.
demounting chain
guard)
35 Installing or
removing electric
motor
60
Closed chain guard –
plastic
25 Crankshaft 45 Measuring and
charging battery
10
Chain guard 20 Pedals (pair) 10 Installing or
removing battery
60
Chain guard (e-bike) 25
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Repair and Maintenance Information. Version 1.00, 02-07-2018
3. General work units for ATB/race/hybrid
TYRES AVERAGE
MINUTES
BRAKES AVERAGE
MINUTES
CRANKSHAFT AVERAGE
MINUTES
Repairing front or rear
inner tyre
15 Replacing and adjusting: Mounting and
adjusting cleats
15
Replacing front or rear
tyre
15 Front or rear brake pads 10 Replacing:
Rear tyre – aluminium
frame
20 Mounting front or rear V
Brake
20 Left crank 15
BAGGAGE Mounting front or rear
cantilever brake
25 Right crank – single
blade
15
Replacing carrier
(including light)
15 Mounting front and rear
hydraulic brakes
90 Right crank –
multiple blades
30
SHIFTERS BRAKE GRIPS Crankshaft 35
Replacing: Replacing: Pedals 10
Front derailleur (incl.
cable mounting)
20 Common race (incl.
handlebar tape)
40 LIGHTING
Rear derailleur (incl.
cable mounting)
30 Race with integrated
gearing (incl. handlebar
tape)
50 See work units ‘City bike /
E-bike’
COMPUTER Common ATB 15
Mounting computer 10 ATB with integrated
gearing
25 WHEELS
DERAILLEUR LOCKS Replacin and
cleaning pinion
or cassette (incl.
replacing chain and
(de)mounting rear
wheel)
40
Replacing front or rear
derailleur
25 Mounting lock or U-lock 10
FRAME ART ring lock 25 Replacing cassette
body integrated
in hub (incl. (de)
mounting rear
wheel
45
Replacing: HANDLEBAR
Frame (incl. milling) 120 Replacing and adjusting: Hub cleaning, adjusting,
replacing traces of wear:
Frame with
mudguards, carrier etc.
180 Straight handlebar 25 Front or rear wheel 30
CABLES Race handlebar (incl.
handlebar tape)
40 Wheel weaving:
Replacing and adjusting: Handlebar tape 15 Equal flange height 45
Inner cable V-brake 10 Mounting bar ends 15 Unequal flange
height
50
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Repair and Maintenance Information. Version 1.00, 02-07-2018
TYRES AVERAGE
MINUTES
BRAKES AVERAGE
MINUTES
CRANKSHAFT AVERAGE
MINUTES
Inner cable cantilever
brake
15 Mounting aerobar 25 Eccentric 60
Outer cable front or
rear brake –
15 Headset (excl. milling) 30 Adjusting hub or
derailleur
15
Straight handlebar Front fork (incl. milling) 50 MUDGUARDS
Outer cable front or
rear brake – race
25 Suspension front fork 45 Press up system 15
Handlebar (incl.
handlebar tape)
Stem 10 Regular mounting
front and rear
30
Front or rear derailleur 15 Handle grip 5
CHAIN
Replacing, fitting,
cleaning (incl.
replacing pinion or
cassette and mounting
rear wheel)
40
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Repair and Maintenance Information. Version 1.00, 02-07-2018
4. Torque table
If a torque is marked permanently on a component, this value must be used instead of the following values in
the tables.
Table 1: standard tightening torques (Nm):
STEEL AND STAINLESS STEEL
COMBINATION
STEEL OR STAINLESS STEEL IN
COMBINATION WITH ALUMINIUM
NM NM
M4 1.5 - 2 1.5 - 2
M5 3 - 4 3 - 4
M6 6 - 7 5 - 6
M8 12 - 15 7 - 9
M10 30 - 35 10 - 12
Table 2: Torque overview for bike specific parts [Nm]
Rear derailleur fixation bolt M10x1 8 - 10
Rear derailleur cable clamp 5 - 7
Rear wheel nuts 30 - 45
Pedals 35 - 55
Front mudguard stay 1.5 - 1.7
Magura braking levers 3.5 - 4.5
Shifters on handlebar 2.2 - 2.7
Saddle bolts 7 - 8
Bosch motor bolts M8*60 25-30
Bosch motor plate M6*15 Torx T30 13 -15
Chainring nut (left hand thread) 30
Crank arms 47-52
Bosch display + lamp bracket and remote control screws 1
Battery holders M5*25 5
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Repair and Maintenance Information. Version 1.00, 02-07-2018
5. Fork Maintenance guide
UNICONPrμF™
UNICON
PrμF™ System
PrμF™
●
●
●
⚠
⚠
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Repair and Maintenance Information. Version 1.00, 02-07-2018
6. List of interchangeable parts
Guidelines for replacement of speed e-bike/pedelec parts up to a pedal assist of 45 km/h (28 mph)
CATEGORY
Important basic information
CATEGORY
Components which may only be replaced upon
presentation of valid test report (parts approval
(ABE*, EC, ECE) or part certificate
- Speed e-bikes with a motor assistance of up to
45 km/h (27 mph) are considered motor vehicles
and subject to EU Directive 2002/24/EC or EU
Regulation No. 168/2013.
- Depending on the vehicle there may be dierent
requirements which must be strictly observed
when replacing a component. Therefore, always
check the indications given in the vehicle
documents prior to doing any work on the
vehicles.
- Note: At present, vehicles with an individual
operating licence are mainly subject to the
regulations of the EU Directive 2002/24/EC.
- All components which are not included in the list
may only be replaced by original spare parts of
the vehicle and/or component manufacturer.
Handlebar-stem unit
Provided that there is no need to change the lengths
of cables and/or hoses, modification of the seating
position to suit the user should be possible within
the original cable lengths. Any further modification
results in a significantly changed load distribution
on the bicycle and entails potentially critical steering
properties.
Seat post
Provided that the oset to the rear does not exceed
20 mm with regard to the series/original field of use,
note that a modified load distribution beyond the
intended setting range may possibly lead to critical
steering properties. The length of the saddle rails at
the saddle structure as well as the saddle shape are
also important.
Headlight
With valid type approval, identical mounting position
as well as EMC proof only.
Rear light with brake light and licence plate light, if
applicable
With valid type approval and identical mounting
position only, if tested in accordance with ECE-R 50
as well as EMC proof.
Reflector
With valid type approval only.
Rear view mirror
Only if tested in accordance with ECE-R 81 and
identical mounting position.
Acoustic signalling device (horn)
Only if tested in accordance with ECE-R 28 and
identical mounting position.
Pedals
Vehicles with 168/2013 approval.
*ABE: general type approval
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Repair and Maintenance Information. Version 1.00, 02-07-2018
CATEGORY
Components which may be replaced under the
conditions described below
CATEGORY
Special notes for mounting accessories
Pedals
Including approved reflectors, provided the pedal is
not wider than the series/original pedal (vehicle with
2002/24/EC approval).
Tyres
As specified in vehicle documents, either in
accordance with ECE-R 75 or with approval of tyre
manufacturer.
Grips with screw clamps
In this case, the vehicle width must not be modified.
Headset
Bottom bracket
Rear and front derailleur
All gear change parts must be suitable for the
number of gears and mutually compatible.
Shift levers / Twist grip
Provided that the position on the handlebar remains
unchanged.
Cables and housings
Chain wheels / Belt sprockets / Cassette sprocket
Provided that the number of teeth and the diameter
is identical to the series/original field of use.
Chain guard
Provided that it is free of sharp outer edges and
complies with the Delegated Regulation No.44/2014,
Annex VIII. The clearance to the tyre, which should
be 10m at least, must also be taken into account.
Spokes
Provided that the dimensions correspond to the
original part.
- Additional battery/rechargeable battery-operated
headlights are not permissible.
- Trailers are only permissible, if a trailer load is
entered under no.17 of the certificate of conformity
and a coupling device under no. 43.1. Note: The
maximum permissible trailer load is 50% of the
tractor vehicle’s empty weight (without batteries).
There are only 50mm ball coupling devices
possible.
- Transporting children in a trailer is forbidden in
general.
- For safety reasons, it is strongly recommended not
to mount child seats.
- Due to the undefined load and load distribution, it
is strongly recommended not to use baskets.
- Bags without permanent attachment are
considered cargo and permissible. However, an
adequate load distribution must be observed in
this case.
- Top cases on the luggage carrier are permissible,
provided that the luggage carrier’s bearing load is
observed.
Inner tube
Provided that the dimensions correspond to the
original part.
Crank arm
Provided that the length and the dimensions, e.g.
crank arms/ frame centre (Q-factor) are observed.
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Repair and Maintenance Information. Version 1.00, 02-07-2018
CATEGORY
Components which may be replaced in
consideration of the conditions described below
CATEGORY
Special notes for mounting accessories
Chain / Toothed belt
Provided that the original width is observed.
Rim tape
Rim tapes and rims must be compatible. Modified
combinations may result in rim tape shifting and thus
defective inner tubes.
Saddle
Provided that the oset to the rear does not exceed
20 mm with regard to the series/original field of use,
note that a modified load distribution beyond the
intended setting range may possibly lead to critical
steering properties. The length of the saddle rails at
the saddle structure as well as the saddle shape are
also important.
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Repair and Maintenance Information. Version 1.00, 02-07-2018
7. Wiring diagrams
Motor +
Controller
L brake
Sensor
Charging
Socket
Display
Remote
Control
Horn
Button
Headlight
Horn
R brake
Sensor
Speed
Sensor
Rear light
Lic. Plate light
Brake light
Battery
DownTube + Frame Bracket
Handlebar
Luggage carrier
ChainStay
7
5
2
1
3
4
6
8
9
10
11
12
13
Number
Description
Gazelle
Article numbers
Bosch Performance Line Speed Drive Unit
Bosch : 0275.007.041
998702500
PowerTube
500 Vertical Black
Bosch : 0275.007.540
998610000
Plug in
Charging Socket 100mm
Bosch : 1270.016.509
998610400
kit Bosch 0275.007.442
PowerTube
Cable 820mm w/o Charging Socket
Bosch : 1270.016.507
998610300
Speed Sensor Cable 415mm
Bosch : 1270.020.802
998200100
Intuvia
Performance Line Anthracite (Kit; Cable 1500mm)
Bosch : 0275.007.813
998607000
Kit including Rear light,
brake light and licence plate light
Approval E1 50R 003427 and E1 50R 003982
447188200
Kit including
Horn and Horn Button
Approval E1 000740
444409600
Kit Headlight + Horn + Button
Headlight Busch and Müller IQ
-X E
Approval E1 014416
444409600
Kit Headlight + Horn + Button
ySplit
cable with two double female Mini B Higo connectors
596406400
brakes with short brake sensor cable (BSC)
or 596406200
Light Cable
Rear 1400mm
Bosch : 1270.020.324
998101300
Light Cable Front 1400mm
Bosch : 1270.020.322
Included
in 44409600
Headlight kit
Brake
sensors on Magura MT4e brake levers with double male mini B Higo
connectors
Front : 448324200
(Short BSC)
448325100
(Long BSC)
Rear
: 448324300
(Short BSC)
44832520
(Long BSC)
7
5
2
1
3
4
6
8
9
10
11
12
13
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Repair and Maintenance Information. Version 1.00, 02-07-2018
8. Component & diagnostic information
Diagnostic information is available after training at one of the Bosch training facilities. Dealers in Germany,
Switzerland, Denmark, Finland, Norway, Sweden, Belgium, the Netherlands, Italy, the UK, Spain, France and
Austria can register for training sessions via their service partner’s web shop at www.bosch-ebike.com/
webshop (all countries except Switzerland) and www.bosch-ebike.ch/webshop (Switzerland).
For more information about the Bosch system and diagnostic information see Bosch manual
www.gazellebikes.co.uk/media/6942/gaz_bosch_uk_171_v01.pdf
9. Diagnostic fault-codes
For more information about Bosch diagnostic fault codes see Bosch manual:
www.gazellebikes.co.uk/media/6942/gaz_bosch_uk_171_v01.pdf
10. Software versions
For more information about the Bosch software versions see:
www.bosch-ebike.com/en/service/software-update/
11. Special tools and equipment
Special diagnostic software and equipment can be applied for after the training by Bosch has been followed.
See paragraph 3.
12. Customer technical support
For customer technical support call:
The Netherlands 0900 - 707 07 07
Belgium +32 (0)3 480 06 49
Germany +49 (0)2 161 91 833 18
Denmark +45 (0)3 688 01 52
Austria +43 (0)7 208 80 615
France +33 (0)8 050 841 99
Swiss: +41 (0)41 748 55 55
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Repair and Maintenance Information. Version 1.00, 02-07-2018
13. Royal Gazelle Maintenance schedule
CUSTOMER NAME VIN NUMBER
ORDER NUMBER DEALER SIGNATURE
BEFORE
EVERY RIDE
EACH
KM
EACH
OR ONCE A YEAR
Check tyre pressures & add air if needed. The tyre
pressure should at all time be in the range indicated
on the tyre. Tyre pressure can influence the electric
support range and the riding comfort
x
Check the tyre tread for wear and embedded debris
that could cause a flat. A replacement tyre should
be of the ETRTO dimension that is mentioned in the
certificate of compliance (COC) for the vehicle.
x
Check safety-related accessories: horn, headlight,
rear light, brake light, reflectors
x
Check that the wheel quick releases are tight and
that the wheels are secure
x
Spin wheels looking for wobbles x
Test brakes to make sure they are gripping and
check to see that the brake pads are in good
condition. If the brake pads are worn, they should be
replaced with original spare parts.
x
Check chain & grease if it looks dry x
Compress and release the suspension to check that
it's working properly.
x
Check for chain, cassette cog and chain ring wear
and replace worn parts as required. Replacement
parts should be compatible with the drive train
and have the same number of teeth as those fitted
originally.
x
Clean the drive train (chain, chain rings, cassette,
sprocket, rear derailleurs, chain tensioner) and
regrease
x
Check the wheels for loose spokes x
Clean the bike and inspect the frame and
components for signs of wear such as cracks
x
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Repair and Maintenance Information. Version 1.00, 02-07-2018
BEFORE
EVERY RIDE
EACH
KM
EACH
OR ONCE A YEAR
Use a torque wrench to check the tightness of the:
motor bolts, crank arm bolts, pedals, chain ring bolts,
saddle bolts, seat post bolts, stem bolts, handlebar
bolts and all accessory mounting bolts/screws.
Refer to the tightening torque table for the correct
tightening torques
x
Grease the cables to prevent binding and check
the cables for fraying and rusting and replace if
necessary
x
Maintain and grease your suspension components:
Hold the front wheel blocked with the brakes and
push the vehicle forwards and backwards to ensure
there is no excessive play in the front fork. If needed,
adjust the front fork play as described in the fork
maintenance guide
x
Check all bearing systems: hubs, headset and
pedals: adjust and/or overhaul as needed
x
Clean and check wheels carefully for signs of wear
or cracks at the spoke nipples
x
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Repair and Maintenance Information. Version 1.00, 02-07-2018
14. Royal Gazelle Maintenance Record
CUSTOMER NAME VIN NUMBER
ORDER NUMBER DEALER SIGNATURE
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
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Repair and Maintenance Information. Version 1.00, 02-07-2018
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
Service/repair date:
km:
Type of service: maintenance / repair
Work done, parts replaced:
Dealer/service operator stamp & signature:
17
Publisher © Koninklijke Gazelle N.V.
After Sales
All rights reserved. Not to be reprinted, translated or duplicated
either wholly or in part without prior written permission. Errors
and omissions excepted; subject to technical amendment.
ROYAL DUTCH Gazelle N.V.
Wilhelminaweg 8
6951 BP Dieren
The Netherlands
www.gazellebikes.com
GAZ_RM INFORM_EN_18.1
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