Whyte E-150 Assembly instructions

E-MTB Full Suspension Bike Range
Page 3 Whyte Supplementary Service Manual
Page 37 BOSCH Drive Unit
Page 45 BOSCH PowerTube Battery
Page 57 BOSCH Charger
Page 67 BOSCH Purion Display
Page 75 BOSCH Error codes

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Table of Contents
1.0 Introduction
2.0 Geometry
3.0 Preparations for riding:
3.1 Making Adjustments
3.2 Whyte Inter Grip Seat Clamp Adjustment
3.3 Set up of Fork
3.4 Set up of Rear Damper
3.5 Suspension Tuning Log
4.0 Safety.
5.0 Lubrication:
5.1 Whyte Inter Grip Seat Clamp
5.2 General Lubrication
6.0 Servicing the Rear Suspension:
6.1 Removing the Rear Shock and Swinging Arm.
6.1.1 Remove the Rear Shock only.
6.1.2 Remove the other rear suspension parts.
6.1.3 Remove the chain-stay & bearings from the Main Frame
6.2 Stripping and Re-assembling Other Rear Suspension Bearings
6.2.1 Extraction of Bearings
6.2.2 Insertion of Bearings
6.2.3 Re-Assembly of Shield Washers / Spacers
6.3 Re-assembling the Rear Suspension
6.3.1 Re-Assembly of the Rear Suspension.
6.3.2 Insert the bearings into the Main Frame, plus
assemble the chain-stays to the Main Frame.
6.3.3 Re-assemble the other rear suspension parts.
6.3.4 Re-assemble the Rear Shock into the Main Frame.
6.2.4: Application of “SKF LGAF 3E” or “Castrol Optimol T”
Anti-Fret Pastes.
7.0 Servicing the Whyte Modular Dropout Systems:
7.1 Disassembly of Modular Rear Dropouts.
7.1.1 Shimano E-Thru
7.1.2 SRAM Maxle 148mm
7.2 Reassembly of Modular Rear Dropouts.
7.2.1 Shimano E-Thru
7.2.2 SRAM Maxle 148mm
8.0 Servicing the Whyte Inter Grip Seat Clamp

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1.0: INTRODUCTION
Thanks for choosing to purchase this Whyte product. We hope you will enjoy all
the benefits its advanced design and engineering will bring to your riding experi-
ence.
This manual will guide you through the set-up, safety and maintenance proce-
dures that are specific to your Whyte bike. For other more general information,
we strongly advise that you also read thoroughly the General Instruction Manual
that is also supplied with your new bike.
Also, please note that the specification of all the components that are fitted to
your bike as standard may be obtained from the Whyte Bikes Brochure or alter-
natively from the Whyte Bikes website www.whyte.bike
Please remember, if you are in any doubt about your ability to safely service or
repair your Whyte bike, do not ride it and instead arrange for a professional bicy-
cle mechanic at your local Whyte dealer to do the job correctly.
Bundled with this manual, are the respective manufacturers instructions and
manuals for the branded parts and systems that are fitted to your Whyte bike.
Please take time to study all the relevant instruction manuals to ensure you have
a continually safe and well set-up bike before every ride, and to help you build up
a relationship of knowledge between you and your Whyte Dealer.
Happy and safe riding,
Whyte design team
2.0: GEOMETRY
The geometry of the full suspension range of Whyte Bikes is available from the
Whyte Bikes website www.whyte.bike
WHYTE Service Manual
9.0 Fitting Internal Cables & Hoses.
9.1 To replace cable or hose outers.
9.2 To fit a “Dropper” seat-post with internal cable.
10.0 Removal of Battery
10.1 Location of Bosch Battery On/Off Button.
10.2 Location of Bosch Battery Charge Port.
11.0 Torque Settings.
12.0 Owner’s Notes
Table of Contents (continued)

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WHYTE Service Manual
3.0: PREPARATIONS FOR RIDING
3.1: MAKING ADJUSTMENTS
Please refer to the specific component
manufacturers manual or published tech-
nical information about adjusting, servic-
ing or replacing the components on your
Whyte bike. Instructions may be down-
loaded from the relevant manufacturer’s
internet website, as shown in the table to
the right.
In addition, we recommend that you
should also read carefully the advice pub-
lished by Bosch e-bike systems about
operation of the Bosch e-Bike systems
fitted to the Whyte e-MTB. Failure to do
so could result in Serious Injury or Death.
For additional advice on general care of e-
bikes, Visit:
www.bosch-ebike.com/en/news/care-of-ebikes/
CAUTION! If you are uncertain in any way, about making adjustments to
any components or systems on you Whyte bike, then DO NOT RIDE YOUR
BIKE. Contact your Whyte dealer who will be able to advise you on how to
go about setting up you Whyte bike for riding, and or making adjustments
to the components fitted to your Whyte bike.
3.2: WHYTE INTER GRIP SEAT CLAMP ADJUSTMENT & SERVICE
Tools Required: 5mm Hex Key
Torque Wrench (Ranging from 3Nm to 15Nm)
SKF LGEP2 or Castrol Spheerol AP3 or Finish Line Teflon White
Lithium
Complex grease
The Inter Grip seat clamp design is present on some models of Whyte full suspen-
sion mountain bikes. It allows adjustment of the saddle height & direction.
CAUTION! Avoid over-tightening the seat clamp.
In particular, “dropper” Seat Posts may not work correctly if the seat clamp
is over tightened.
Bosch www.bosch-ebike.com
Crank
Brothers
www.crankbrothers.com
DT Swiss www.dtswiss.com
Formula www.formulahubs.com
Fox www.foxracingshox.com
Joytech www.joytech.co.tw
Maxxis www.maxxis.com
Race Face www.raceface.com
SR Suntour www.srsuntour-cycling.com
SRAM www.sram.com
WTB www.wtb.com

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WHYTE Service Manual
To adjust the Seat height and/or direction, using the 5mm Hex Key, undo the M6
Capscrew (1) just enough to allow the Seat Post to slide freely up and down. Set the
height and/or direction to the desired level. Re-tighten the M6 Capscrew (1), using
the 5mm Hex Key and Torque Wrench, to the 14Nm limit, as marked on the Plain
Sleeve (4).
If a “dropper” Seat Post is fitted, simultaneously depress the activation trigger and
press down on the Saddle to compress the Seat Post until it is fully compressed. Then
release the activation trigger and the Seat Post should rise up automatically. If this
does not happen, gradually loosen the M6 Capscrew (1) with the %mm Hex Key be-
low the 14Nm limit, until the Seat Post rises automatically. Then firmly twist the Sad-
dle to confirm the Seat Post is still securely gripped by the lowered torque value that
allows the “dropper” Seat Post to function correctly.
CAUTION! When adjusting the saddle height you MUST obey the Minimum
insertion depth requirement marked on the Seat Post. Also consult the manu-
facturers Seat Post instructions in conjunction with these notes.
3.3: SET UP OF FORK
Tools Required: Good Quality Shock Pump.
Small Ruler
The Front Suspension Fork fitted to your Whyte bike will be pre-set with the standard
settings. Before riding, you may need to adjust these setting. First is the Sag setting
on the fork. This is to ensure the forks are set-up correctly for your own body weight,
allowing the fork to perform as intended.
To set Sag on the Fork, you need to measure the amount the Fork compresses when
you sit on the bike in the normal riding position.
Refer to the specification tables in the relevant Fork manufacturers set up instruc-
Ite
mDescription
1Cap-screw, M6 x 30mm
long.
2Inter-Grip Sleeve,
threaded.
3“O” Ring seal, fits in
sleeve groove.
4Inter-Grip Sleeve, no
thread.
5 Inter-Grip Pad for
Ø30.9mm Seat Post.
Fig.1: Inter-Grip Seat Clamp

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WHYTE Service Manual
tions to find how to adjust the air spring pressure. Using a Shock pump, either add
or remove air until Sag is correctly set.
Please note that for the detailed instructions for servicing and all matters relating
to the Forks fitted to your Whyte bike, please refer to the relevant manufacturers
instructions.
Rebound Damping adjustment:
This adjustment fine-tunes the speed at which the wheel returns to its normal ride
height after hitting a bump. Refer to the relevant manufacturers instructions to find
out how to adjust the rebound damping. To demonstrate the effect of this function,
turn the adjuster to its slowest setting. Press down on the handlebars to compress
the Forks, then release the load. The suspension recovers very slowly to its original
position.
Repeat the above with the adjuster turned to the fastest setting and the difference
will be seen immediately the load is released. We recommend the optimum setting
is to adjust the re-bound damping to be as slow as possible, but not so slow that
the normal ride height is not recovered. On very rough terrain, if the bike becomes
progressively lower as more bumps are hit then the re-bound damping is set too
slow. On the other hand if the bike feels choppy and not plush then the re-bound
damping is too fast. A bit of trial and error is needed to get the exact setting.
IMPORTANT SAFETY NOTE:
Always stop riding when making adjustments of
any kind to the bicycle!
3.4: SET UP OF REAR DAMPER
Tools Required: Good Quality Shock Pump.
Small Ruler
Your Whyte bike is fitted with either an air spring or a coil spring rear Shock. This
means that for an air Shock, the air pressure in the shock absorber determines the
spring rate and on a coil Shock, the rating of the spring determines the spring rate.
The correct ‘sag’ can be found using the sliding ‘O’ ring fitted to the shaft of the
Shock piston. Slide the ‘O’ ring against the Shock body. Then gently sit on the bike
in your normal riding position and with normal riding gear, including back pack if
applicable, and also raise your feet off the floor. Carefully dismount and measure
the distance the ‘O’ ring has moved away from the Shock body.
The optimum distance for the Quad-Link rear suspension system is shown in the
table to the right. If there is less than that distance fit a Shock pump and release
air pressure. Conversely if there is greater than that distance, fit the Shock pump
and increase air
Repeat the ‘sag’ test until the recommended sag distance is achieved.
For Coil Shock, the spring rate adjustment is made by swapping the spring for a
higher or lower rate spring. If more sag is required, swap the spring for a lower
Model Sag @ 30%
E-150 16.5mm
E-180 19.5mm

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WHYTE Service Manual
rate spring. If less sag is required, swap the spring for a higher rate spring.
Rear Suspension Set-up - Rebound Damping:
When the damper unit is being compressed, this is known as the compression stroke.
As the suspension unit recovers from compression back towards its full length, this is
called the re-bound stroke. All the shocks fitted as standard to the Whyte full suspen-
sion mountain bikes have factory set compression damping, and manually adjustable
rebound damping.
Rebound Damping Adjustment:
The advice in section 3.3 about the fork rebound damping adjustments also applies to
the rear shock.
IMPORTANT SAFETY NOTE:
Always stop riding when making adjustments of any kind to the bicycle!
Platform Damping Adjustment.
The rear Shock fitted to your Whyte bike may have a “platform” facility to adjust the
slow speed compression damping, eg Fox “3pos w/Adj” or SRAM RockShox “Motion
Control”. Please refer to the relevant shock manufactures technical information to
learn how to adjust these features.
Please note, that the Whyte rear suspension systems have been designed not to rely
on excessive low speed compression damping to obtain efficient pedalling perfor-
mance, and turning on too much low speed damping on the rear shock will compro-
mise the suspensions sensitivity to small bump absorption and traction.
3.5: SUSPENSION TUNING LOG
Record your best suspension settings in the table below, to restore them if necessary,
eg. after dealer servicing of the suspension or if a friend has borrowed your bike.
Date
Rider Weight
(including all
riding kit)
(kg or lbs)
Fork Pres-
sure
(bar or P.S.I)
Fork Rebound
Damping
(# of clicks from
softest setting)
Shock Pressure
(bar or P.S.I)
Shock Rebound
Damping
(# of clicks from
softest setting)

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WHYTE Service Manual
4.0: SAFETY
IMPORTANT: The following are intended to be advisory notes on the safe
use of your Whyte bike. You should also read thoroughly the General In-
struction Manual also supplied with your new bike. If at any stage you are
uncertain about the safety or safe operation of the bike as a whole, or any specific
component, then DO NOT RIDE YOUR WHYTE and instead please consult the
specific component manufacturers instruction manual or your Whyte Dealer for
advice.
Maximum Weight Limit:
18st. / 114kg (including rider’s pack and all riding equipment )
WARNING: As is the case with all mechanical components, the bicycle is
subjected to wear and high stresses. Different materials and components
may react to wear and stress fatigue in different ways. If the design life of a
component has been exceeded, it may fail suddenly causing possible injury
to the rider. Any form of crack, scratches and decolouring in high stress are-
as are showing that the component has exhausted its life time and has to be
replaced. If you are in any doubt about one or more components on your
Whyte DO NOT RIDE YOUR BIKE. Consult the specific component manu-
facturers literature, or take your bike to your local Whyte Dealer.
WARNING: Your Whyte eMTB has been fitted with a Bosch e-MTB e-bike
systems. We strongly recommend that you read, understand and adhere to
the instructions contained in the following Bosch manuals and literature:
• Remote Handlebar control unit
• Battery and Battery Charging
• Drive Unit
• E-Bike Care.
Failure to understand and operate the Bosch components correctly
could result in serious injury or death.
Designed for the following use:
The Whyte eMTB range of bicycles have all been designed, tested and comply with
EN-15194:2017 Safety Standard, for typical mountain biking use.

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5.0: LUBRICATION
Please refer to the Whyte General Instruction Manual for guidance about lubricating
many of the components on your Whyte bicycle.
For the range of bicycles contained in this Supplementary Service Manual, there is
also the following specific guidance:
5.1: WHYTE INTER GRIP SEAT CLAMP
5.2: GENERAL WHYTE LUBRICATION
For the correct lubrication regime and maintenance of all parts on a Whyte bicycle,
please refer to the specific component manufacturers detailed instructions bundled
with this manual or for further information visit the specific manufacturers website.
6.0: SERVICING THE REAR SUSPENSION
6.1: Remove the Rear Shock, Links & Swinging Arm:
Tools Required: 2x 4mm Hex Key
1x 5mm Hex Key - Ball ended
1x 6mm Hex Key
1x 8mm Hex Key
2x T-25 Torx® Keys
WHYTE Service Manual
Figure 2: Capscrew Lubrication
Item Lubricant Lubrication
Interval
Description
1SKF LGEP2 or Castrol Spherol AP3 or Finish
Line Teflon White Lithium Complex grease Once a Month
M6 x 30mm
Capscrew

Page 112019
Item Description
1M5 x 16mm long Socket-head Capscrew (T-25 Torx®)
2Collar for M5 Capscrew
3Hollow Pivot Pin Ø8mm x 31mm long
4Flanged Nut M12 x 19mm long
5Flanged Screw M12 x 15mm long
6Rear Shock Absorber
7Shock Extender
8 M15 x 26mm long Pivot Screw, 15mm Thread (6mm A/F Internal Hex)
9M15 x 26mm long Pivot Screw, 15mm Thread (6mm A/F Internal Hex)
10 M6 x 20mm long Capscrew (5mm A/F Internal Hex)
11 Tapered Sleeve for Expanding Collet
12 Pivot Pin 80mm long, expanding collet, M15 thread.
13 M15 x 26mm long Pivot Screw, 10mm Thread (6mm A/F Internal Hex)
14 Chain-stays
15 Main Frame
16 Rear Suspension H Link, 99mm centre — to – centre
17 M15 x 25mm long Pivot Screw, 10mm Thread (6mm A/F Internal Hex)
18 Seat-stays
19 Shield Washer (O.D. 23mm)
20 Bearing (Enduro 6802-2RS-MAX)
21 Internal Spacer (49mm long)
22 M15 x 27mm long Pivot Screw, 14mm Thread (6mm A/F Internal Hex)
WHYTE Service Manual

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WHYTE Service Manual
Figure 3: Disassembly of the
Rear Suspension (First Stage)
6.1.1 To remove only the rear Shock (6) from the frameset
IMPORTANT: When removing Rear Shock and/or Seat & Chain stays al-
ways brace the rear end and Shock to prevent damage to frame when
weight is removed.
Whilst referencing figure 3, using the T-25 Torx® Keys, undo the two M5 x 16mm
long Socket-head Capscrews (1) from the Ø8mm x 31mm long Hollow Pivot Pin (3)
that passes through the Main Frame (15) and front of the Rear Shock (6). Which-
ever Capscrew (1) becomes undone first, remove it and the adjacent Collar (2),
and pull the Pivot Pin (3) all the way out from the other side.
Using the 6mm Hex Key and the 8mm Hex Key, undo and remove both the
Flanged Nut M12 x 19mm long (4) from the Flanged Screw M12 x 15mm long (5),
that pass through the Shock Extender (7) and the rear of the Rear Shock (6). You
can now remove the Rear Shock (6).

Page 132019
6.1.2 To remove the Link (16) & Swinging Arm (14) from the Main Frame
(15).
Whilst referencing figure 3 & 4, using the 6mm Hex Key, unscrew and remove the
M15 x 26mm Flanged alloy Screws (8 and 9) from the front of the H Link (16).
Next, using the 6mm Hex Key, unscrew and remove the two M15 x 27mm Flanged
alloy Screws (22) at the rear of the Chain-stays (14). Be careful to retain all the
Shield Washers (Items 2 & 3, Figure 7) ready for re-assembly.
To separate the Seat-stays (18) from the H Link (16) and Main Frame (15), whilst
referencing figure 4, using the 6mm Hex Key, unscrew and remove the two M15 x
26mm Flanged alloy Screws (13) at the front of the Seat-stays (18). The Seat-
stays (18) may now be removed from the H Link (16). Finally to remove the Shock
Extender (7) from the H Link (16), using the 6mm Hex Key, unscrew and remove
the two M15 x 25mm Flanged alloy Screws (17). Be careful to retain all the Shield
Washers (Items 2 & 3, Fig 7) ready for re-assembly.
WHYTE Service Manual
Figure 4: Disassembly of the Rear Suspension (Third Stage)

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WHYTE Service Manual
6.1.3 To remove the Chain-stays (14) and Bearings (20) from the Main
Frame (15).
Whilst referencing figure 5, using the 5mm Hex Key, partially unscrew the M6 x
20mm long Capscrew (10) from the Pivot Pin 80mm long, expanding collet, M15
thread (12). Using the 6mm Hex Key, unscrew and remove the Pivot Pin 80mm
long, expanding collet, M15 thread (12). The capscrew (10) may now be completely
removed, to allow the tapered sleeve (11) to be released from the collet (12).
The Chain-stays (14) may now be removed from the Main Frame (15). Be careful to
retain the two Shield Washers (19) ready for re-assembly.
Using the press tools shown in Figure 19, extract the BOLU-WB0025
bearings (20) from both sides of the Main Frame (15). Align the removal tool care-
fully with the slots in the Spacer (21).
Figure 5: Disassembly of the
Rear Suspension (Third Stage)

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6.2: STRIPPING AND REASSEMBLING OTHER BEARINGS.
(Reference figures 6 & 7)
Figure 6: Assembly of Link
Item Description
1ID 15mm, OD 24mm, Width 5mm, bearing
(BOLU-WB0025)
2Shield washer (O.D. 20mm)
3Shield washer (O.D. 23mm)
4Various centre-to-centre dimensions Alloy Link Bodies
WHYTE Service Manual

Page 16 2019
Figure 7: Assembly
of the Seat-stays
Item Description
1ID 15mm, OD 24mm, Width 5mm, bearing
(BOLU-WB0025)
2Middle shield washer (O.D. 20mm)
3Outer shield washer (O.D. 23mm)
4Right Seat-stay
5Left Seat-stay
WHYTE Service Manual

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Figure 8: Bearing Insertion & Extraction 6802-2RS-MAX
(Link or Rear of Seat Stay)
Item: Description.
1 M8 Capscrew ISO4162 55 long
2M8 Washer ISO 7089
3M8 Nut ISO 4032
4BOLU-WB0025 Bearing
5BOLU-WB0025 Bearing Tool 1
6Mating Component (ie: Link or Seat-Stay)
7BOLU-WB0025 Bearing Tool 2
WHYTE Service Manual

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WHYTE Service Manual
Figure 9: Bearing Insertion & Extraction 6802-2RS-MAX
(Above Main Frame Bottom Bracket)
Item: Description.
1M8 Capscrew ISO4762 55 long
2M12 Nut ISO 4035
3I. D. 12 Washer ISO 7089
4BOLU-WB0025 Bearing
5 BOLU-WB0025 Bearing Tool 1
6Mating Component (ie: Bottom Bracket Yoke)
7BOLU-WB0025 Bearing Tool 2
8Internal Bearing Spacer

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6.2.1: EXTRACTION OF BEARINGS
Tools required: Either 6802-2RS-MAX or 15268-2RS_MAX Bearing press tool
6mm Hex Key
10mm Hex Key
13mm A/F Spanner
18mm A/F Spanner
To remove the Bearings (4) from the Link or Rear of the Seat-stay (6). Assemble
the parts as shown in figure 8. Using the 6mm Hex Key and 13mm spanner, tight-
en the assembly together until the Bearing (4) is pressed out of the mating com-
ponent (6). Repeat on all other Bearings.
To remove the Bearings (4) from the Bottom Bracket Yoke (6). Assemble the
parts shown in figure 9. Using the 10mm Hex Key and 18mm spanner, tighten
the assembly together until the Bearing (4) is pressed out of the mating compo-
nent (6). Repeat on all other Bearings.
6.2.2: INSERTION OF BEARINGS
Tools required: Either 6802-2RS-MAX or 15268-2RS-MAX Bearing press tool
6mm Hex Key
10mm Hex Key
13mm A/F Spanner
18mm A/F Spanner
Loctite 638
Before inserting the Bearings, make sure all the components are clean from dirt
and have been thoroughly de-greased. To press the Bearings (4) into the mating
component (6) apply a small amount of Loctite 638 to the outside diameter of the
Bearing and to the inside bore of the mating component (6). Next assemble the
components as illustrated in either Figure 8, or 9. It is very important to make
sure the Bearing (4) and Bearing Insertion tool 1 (5) are squarely seated against
the mating component (6). With great care, slowly tighten the M8 Socket head
cap screw (6) with the 6mm Hex Key and the nut (2) with the 13mm Spanner
until you can see the Bearing (4) being pressed squarely into the mating compo-
nent (6). For the assembly shown in figure 9, use the 10mm Hex Key & the
18mm A/F Spanner. Once the Bearing is fully seated an you can no longer tighten
either the M8 or M12 Socket Head Cap Screws further, undo the nut and bolt and
remove any excess Loctite from around the Bearing, particularly in any internal
threads. Repeat for the remaining Bearings.
IMPORTANT! Allow 24 hours for the Loctite to totally cure.
6.2.3: REASSEMBLY OF SHIELD WASHERS / SPACERS
Tools required: SKF LGEP2 or Castrol Spherol AP3 or Finish Line Teflon
White Lithium
-
Complex grease
SKF LGAF 3E” or “Castrol Optimol T” Anti-Fret Paste
Apply a good quantity of SKF LGEP2 or Castrol Spherol AP3 or Finish Line Teflon
White Lithium-Complex grease on top of the Bearings. The grease should com-
pletely cover each Bearing and be applied on both sides of each Bearing when it is
in the Swinging arm component.
WHYTE Service Manual