Bosch Intuvia Verdrahtungsschema

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP SAFE TO CONSULT AT A LATER DATE

22-15-1078, 22-15-1079, 22-15-4001…22-15-4003, 22-15-4025

MY22B01 - 12

_1.0_

26.08.2021

Cross Rider EVO 1, Cross Mover EVO 2, Cross Mover EVO 2 26“

TURBO

SPORT

TOUR

ECO

OFF

MPH

KM/H

Reichweite

AMM

PMWH

MIN

MPH

KM /H

RESET

TURBO

SPOR T

TOUR

ECO

OFF

MPH

KM/H

Reichweite

AMM

P MWH

MIN

MPH

Translation of original operating instructions for

BULLS Pedelecs with BOSCH Intuvia

on-board computer

All manuals and user guides at all-guides.com

MY22B01 - 12_1.0_26.08.2021 1

Contents

1 About these operating instructions

1.1 Manufacturer 10

1.2 Laws, standards and directives 10

1.3 Language 10

1.4 For your information 10

1.4.1 Warnings 10

1.4.2 Markups 10

1.5 Type number and model 11

1.6 Frame number 11

1.7 Identifying the operating instructions 11

1.8 Aim of the operating instructions 12

2 Safety

2.1 Residual risks 13

2.1.1 Risk of fire and explosion 13

2.1.1.1 Rechargeable battery 13

2.1.1.2 Overheated charger 13

2.1.1.3 Hot components 13

2.1.2 Electric shock 14

2.1.2.1 Damage 14

2.1.2.2 Water penetration 14

2.1.2.3 Condensation 14

2.1.3 Risk of a crash 14

2.1.3.1 Incorrect quick release setting 14

2.1.3.2 Incorrect tightening torque 14

2.1.3.3 Incorrect component 14

2.1.4 Risk of amputation 14

2.1.5 Key breaking off 14

2.2 Toxic substances 15

2.2.1 Brake fluid 15

2.2.2 Suspension oil 15

2.2.3 Lubrication oil 15

2.2.4 Defective battery 15

2.3 Requirements for riders 15

2.4 Vulnerable groups 15

2.5 Personal protective equipment 15

2.6 Safety guards 15

2.7 Safety markings and safety instructions 16

2.8 What to do in an emergency 16

2.8.1 Dangerous situation in road traffic 16

2.8.2 Leaked brake fluid 16

2.8.3 Battery vapours emitted 17

2.8.4 Battery fire 17

2.8.5 Oil and lubricant leaks from the rear frame damper 17

2.8.6 Oil and lubricant leaks from the fork 17

3 Description

3.1 Proper use 18

3.1.1 Improper use 19

3.1.2 Permitted total weight (PTW) 20

3.1.3 Environmental requirements 21

3.2 Nameplate 23

3.3 Components 24

3.3.1 Overview 24

3.3.2 Chassis 25

3.3.2.1 Frame 25

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MY22B01 - 12_1.0_26.08.2021 2

Contents

3.3.2.2 Steering system 25

3.3.2.3 Steering headset 25

3.3.2.4 Stem 25

3.3.2.5 Handlebars 26

3.3.2.6 Fork 26

3.3.3 Suspension 27

3.3.3.1 Rigid fork 27

3.3.3.2 Suspension fork 27

3.3.4 Wheel 31

3.3.4.1 Tyres 31

3.3.4.2 Rim 31

3.3.4.3 Valve 31

3.3.4.4 Spoke 32

3.3.4.5 Spoke nipples 32

3.3.4.6 Hub 32

3.3.5 Braking system 33

3.3.5.1 Mechanical brake 33

3.3.5.2 Hydraulic brake 33

3.3.5.3 Disc brake 34

3.3.6 Seat post 35

3.3.6.1 Patent seat post 35

3.3.6.2 Suspension seat post 35

3.3.7 Mechanical drive system 36

3.3.7.1 Chain drive layout 36

3.3.7.2 Belt drive layout 36

3.3.8 Electric drive system 37

3.3.8.1 Motor 37

3.3.8.2 Rechargeable battery 37

3.3.8.3 Frame battery 38

3.3.8.4 Pannier rack battery 38

3.3.8.5 Integrated battery 39

3.3.8.6 Charger 39

3.3.9 Lighting 39

3.3.10 On-board computer 40

3.3.10.1 USB port 40

3.3.11 Control panel 40

3.4 Description of controls and screens 41

3.4.1 Handlebars 41

3.4.2 On-board computer 42

3.4.2.1 Riding light indicator 42

3.4.2.2 Level of assistance indicator 42

3.4.2.3 Charge level indicator (on-board computer) 43

3.4.2.4 Indicator for motor power used 43

3.4.2.5 Gear recommendation indicator 43

3.4.2.6 Tachometer indicator 44

3.4.2.7 Function display 44

3.4.2.8 Journey information 44

3.4.2.9 Additional journey information 44

3.4.2.10 System settings and data 45

3.4.2.11 Additional system settings 46

3.4.2.12 System message 47

3.4.3 Control panel 48

3.4.4 Gear shift 49

3.4.4.1 SHIMANO derailleur gears 49

3.4.5 Hand brake 50

3.4.6 Fork lock 51

3.4.6.1 SR Suntour 51

3.4.7 Battery level indicator (battery) 52

3.4.7.1 Battery level indicator (battery) 52

3.5 Technical data 53

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MY22B01 - 12_1.0_26.08.2021 3

Contents

3.5.1 Pedelec 53

3.5.2 Emissions 53

3.5.3 Bicycle lighting 53

3.5.4 BOSCH Intuvia on-board computer 53

3.5.5 USB port 53

3.5.6 Motor 53

3.5.6.1 BOSCH Performance Line CX 53

3.5.7 Rechargeable battery 54

3.5.7.1 BOSCH PowerTube 400 54

3.5.7.2 BOSCH PowerTube 500 54

3.5.7.3 BOSCH PowerTube 625 54

3.5.8 Tightening torques 55

4 Transporting and storing

4.1 Weight and dimensions for transportation 57

4.2 Designated handles, lifting points 57

4.3 Transportation 58

4.3.1 Using the brake transport securing system 58

4.3.2 Transporting the pedelec 58

4.3.3 Shipping a pedelec 58

4.3.4 Transporting the battery 58

4.3.5 Shipping the battery 58

4.4 Storing 59

4.4.1 Break in operation 59

4.4.1.1 Preparing a break in operation 59

4.4.1.2 Carrying out a break in operation 59

5 Assembly

5.1 Unpacking 60

5.2 Required tools 60

5.3 Commissioning 61

5.3.1 Checking the battery 61

5.3.2 Preparing the battery 62

5.3.2.1 Retrofitting the PowerTube adapter 62

5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 64

5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 65

5.3.3 Preparing the wheel 66

5.3.4 Installing the wheel in the SUNTOUR fork 67

5.3.4.1 Screw-on axle (12AH2 and 15AH2) 67

5.3.4.2 20 mm cross axle 68

5.3.4.3 Q-LOC quick release 70

5.3.5 Preparing the LIMOTEC seat post 71

5.3.6 Fitting the pedals 72

5.3.7 Checking the stem and handlebars 73

5.3.7.1 Checking the connections 73

5.3.7.2 Checking stem is firmly in position 73

5.3.7.3 Checking the headset backlash 73

5.4 Pedelec sale 73

6 Operation

6.1 Risks and hazards 74

6.2 Tips for a greater range 76

6.3 Error message 77

6.3.1 On-board computer 77

6.3.2 Rechargeable battery 80

6.4 Instruction and customer service 81

6.5 Adjusting the pedelec 81

6.5.1 Preparing 81

6.5.2 Pedelec adjustment procedure 82

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MY22B01 - 12_1.0_26.08.2021 4

Contents

6.5.3 Determining the sitting position 83

6.5.4 Adjusting the saddle 84

6.5.4.1 Straightening the saddle 84

6.5.4.2 Adjusting the saddle height 84

6.5.4.3 Setting the saddle height with the remote control 85

6.5.4.4 Adjusting the saddle position 86

6.5.4.5 Adjusting the saddle tilt 86

6.5.4.6 Checking saddle stability 86

6.5.5 Handlebars 87

6.5.5.1 Handlebar width 87

6.5.5.2 Hand position 87

6.5.5.3 Adjusting the handlebars 87

6.5.6 Stem 88

6.5.6.1 Adjusting the handlebar height with quick release 88

6.5.6.2 Setting the quill stem 89

6.5.6.3 Adjusting the Ahead stem 89

6.5.6.4 Adjusting the angle-adjustable stem 90

6.5.7 Ergonomic handles 91

6.5.7.1 Checking handlebar stability 91

6.5.8 Tyres 92

6.5.9 Brake 93

6.5.9.1 Brake handle position 93

6.5.9.2 Brake handle tilt angle 93

6.5.9.3 Determining the grip distance 94

6.5.9.4 Grip distance on a MAGURA disc brake lever 95

6.5.9.5 Grip distance on a MAGURA HS22 brake lever 96

6.5.9.6 Grip distance on a MAGURA HS33 brake lever 97

6.5.9.7 Grip distance on a SHIMANO ST-EF41 brake lever 98

6.5.9.8 Grip distance on a SHIMANO ST-EF41 brake lever 99

6.5.9.9 Pressure point on a MAGURA brake lever 100

6.5.9.10 Retracting the brake linings 101

6.5.10 Gear shift 102

6.5.10.1 SHIMANO shifter 102

6.5.11 Suspension 103

6.5.12 Fork sag 103

6.5.12.1 Adjusting the Suntour fork steel suspension 104

6.5.12.2 Adjusting the Suntour fork air suspension 105

6.5.13 Fork rebound damping 106

6.5.13.1 Adjusting the Suntour fork rebound damping 107

6.5.14 Lighting 108

6.5.14.1 Adjusting the lights 108

6.5.15 Adjust on-board computer 110

6.5.15.1 Attaching the on-board computer 110

6.5.15.2 Removing the on-board computer 110

6.5.15.3 Attaching the on-board computer 110

6.5.15.4 Securing the on-board computer against removal 110

6.5.15.5 Charging the on-board computer battery 111

6.5.15.6 Changing the system settings 111

6.6 Accessories 112

6.6.1 Child seat 112

6.6.2 Trailer 113

6.6.2.1 Approval for trailer with Enviolo hub 113

6.6.2.2 Approval for trailer with ROHLOFF hub 114

6.6.3 Mobile holder 114

6.6.4 Tubeless and airless tyres 114

6.6.5 Suspension fork coil spring 114

6.6.6 Pannier rack 114

6.6.7 Panniers and cargo boxes 114

6.7 Personal protective equipment and accessories for road safety 115

6.8 Before each ride 115

6.9 Straightening the quickly adjustable stem 116

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MY22B01 - 12_1.0_26.08.2021 5

Contents

6.10 Using the pannier rack 116

6.11 Raising the kickstand 117

6.12 Using the saddle 117

6.12.1 Using the leather saddle 117

6.13 Using the pedals 117

6.14 Using the multifunctional handlebars or bar ends 117

6.14.1 Using leather handles 117

6.15 Using the bell 117

6.16 Using the battery 118

6.16.1 Frame battery 118

6.16.1.1 Removing the frame battery 118

6.16.1.2 Inserting the frame battery 118

6.16.2 Pannier rack battery 118

6.16.2.1 Removing the pannier rack battery 118

6.16.2.2 Inserting the pannier rack battery 118

6.16.3 Integrated battery 119

6.16.3.1 Removing the integrated battery 119

6.16.3.2 Inserting the integrated battery 119

6.16.4 Charging the battery 120

6.16.5 Charging the dual battery 120

6.16.5.1 Charging process when two batteries are used 120

6.16.5.2 Charging process when one battery is used 120

6.16.6 Using double battery model with a single battery only 121

6.16.7 Waking the battery 121

6.17 Using pedelec with the electric drive system 122

6.17.1 Switching on the electric drive system 122

6.17.2 Switching off the electric drive system 122

6.18 Using the on-board computer 123

6.18.1 Attaching the on-board computer 123

6.18.1.1 Removing the on-board computer 123

6.18.1.2 Attaching the on-board computer 123

6.18.2 Securing the on-board computer against removal 124

6.18.3 Charging the on-board computer battery 124

6.18.3.1 Charging on the pedelec 124

6.18.3.2 Charging using the USB port 124

6.18.4 Using the USB port 125

6.18.5 Switching on the on-board computer 125

6.18.6 Switching off the on-board computer 125

6.18.7 Using the push assist system 125

6.18.8 Using the riding light 126

6.18.9 Selecting the level of assistance 126

6.18.10 Journey information 126

6.18.10.1 Switching the displayed journey information 126

6.18.10.2 Resetting the journey information 126

6.18.11 Changing the system settings 126

6.19 Brake 127

6.19.1 Using the brake lever 127

6.20 Suspension and damping 128

6.20.1 Adjusting the Suntour compression adjuster 129

6.21 Gear shift 130

6.21.1 Using the derailleur gears 130

6.22 Parking 131

6.22.1 Screwing in the quickly adjustable stem 132

7 Cleaning, servicing and maintenance

7.1 Before each ride 137

7.1.1 Checking the guards 137

7.1.2 Checking the frame 137

7.1.3 Checking the fork 137

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MY22B01 - 12_1.0_26.08.2021 6

Contents

7.1.4 Checking the rear frame damper 137

7.1.5 Checking the pannier rack 137

7.1.6 Checking the guards 137

7.1.7 Checking wheel concentricity 137

7.1.8 Checking the quick releases 137

7.1.9 Checking the suspension seat post 137

7.1.10 Checking the bell 138

7.1.11 Checking the handles 138

7.1.12 Checking the USB cover 138

7.1.13 Checking the lighting 138

7.1.14 Checking the brake 138

7.2 After each ride 139

7.2.1 Cleaning the lights and reflectors 139

7.2.2 Cleaning the suspension fork 139

7.2.3 Caring for the suspension fork 139

7.2.4 Cleaning the pedals 139

7.2.5 Cleaning the brake 139

7.2.6 Cleaning the suspension seat post 139

7.2.7 Cleaning the rear frame damper 139

7.3 Basic cleaning 140

7.3.1 On-board computer and control panel 140

7.3.2 Rechargeable battery 140

7.3.3 Motor 140

7.3.4 Frame, fork, pannier rack, guards and kickstand 141

7.3.5 Stem 141

7.3.6 Handlebars 141

7.3.7 Handles 141

7.3.7.1 Leather handles 141

7.3.8 Seat post 141

7.3.9 Saddle 141

7.3.9.1 Leather saddle 142

7.3.10 Tyres 142

7.3.11 Spokes and spoke nipples 142

7.3.12 Hub 142

7.3.13 Switching elements 142

7.3.13.1 Shifter 142

7.3.14 Cassette, chain wheels and front derailleur 142

7.3.15 Brake 143

7.3.15.1 Brake lever 143

7.3.16 Brake disc 143

7.3.17 Belt 143

7.3.18 Chain 143

7.3.18.1 Chain with all-round chain guard 143

7.4 Servicing 144

7.4.1 Frame 144

7.4.2 Fork 144

7.4.3 Pannier rack 145

7.4.4 Mudguard 145

7.4.5 Servicing the kickstand 145

7.4.6 Stem 145

7.4.7 Handlebars 145

7.4.8 Handle 145

7.4.8.1 Rubber handles 145

7.4.8.2 Leather handle 146

7.4.9 Seat post 146

7.4.9.1 Suspension seat post 146

7.4.9.2 Carbon seat post 146

7.4.10 Leather saddle 146

7.4.11 Hub 146

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MY22B01 - 12_1.0_26.08.2021 7

Contents

7.4.12 Spoke nipples 146

7.4.13 Rim 146

7.4.14 Gear shift 147

7.4.14.1 Rear derailleur articulated shafts and jockey wheels 147

7.4.14.2 Shifter 147

7.4.15 Pedal 147

7.4.16 Caring for the chain 147

7.4.16.1 Caring for the chain and all-round chain guard 147

7.4.17 Caring for the brake 148

7.4.17.1 Caring for the brake 148

7.4.18 Lubricating the eightpins seat post tube 148

7.5 Maintenance 149

7.5.1 Wheel 149

7.5.1.1 Checking the tyre pressure 149

7.5.1.2 Checking the tyres 151

7.5.1.3 Checking the rims 152

7.5.1.4 Checking the nipple holes 152

7.5.1.5 Checking the nipple well 152

7.5.1.6 Checking the rim hooks 152

7.5.1.7 Checking the spokes 152

7.5.2 Checking the brake system 153

7.5.2.1 Checking the hand brake 153

7.5.2.2 Checking the hydraulic system 153

7.5.2.3 Checking the Bowden cables 153

7.5.2.4 Checking the disc brake 154

7.5.2.5 Checking the back-pedal brake 155

7.5.2.6 Checking the rim brake 156

7.5.3 Checking the lighting 157

7.5.4 Checking the stem 158

7.5.5 Check the handlebars 158

7.5.6 Checking the saddle 158

7.5.7 Checking the seat post 158

7.5.8 Checking the chain 158

7.5.9 Checking the chain and belt tension 158

7.5.9.1 Checking the derailleur gears 159

7.5.9.2 Checking the hub gear 159

7.5.10 Checking the gear shift 159

7.5.10.1 Electric gear shift 159

7.5.10.2 Mechanical gear shift 159

7.5.10.3 Checking the derailleur gears 159

7.5.11 Adjusting gear shift 160

7.5.11.1 ROHLOFF hub 160

7.5.12 Bowden-cable-operated gear shift, single-cable 160

7.5.13 Bowden-cable-operated gear shift, dual-cable 160

7.5.14 Bowden-cable-operated twist grip, dual-cable 161

7.5.15 Checking kickstand stability 161

8 Maintenance

8.1 Initial inspection 162

8.2 Maintenance 162

8.3 Component-specific maintenance tasks 162

8.4 Carry out initial inspection 165

8.5 Maintenance instructions 166

8.5.1 Servicing the frame 173

8.5.1.1 Servicing the carbon frame 173

8.5.2 Checking the pannier rack 173

8.5.3 Servicing axle with quick release 173

8.5.4 Maintaining the stem 174

8.5.5 Servicing the gear hub 174

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MY22B01 - 12_1.0_26.08.2021 8

Contents

8.5.5.1 Adjusting the hub with cone bearing 174

8.5.6 Servicing the steering headset 175

8.5.7 Servicing the fork 175

8.5.7.1 Servicing the carbon suspension fork 176

8.5.7.2 Servicing the suspension fork 176

8.5.8 Servicing seat post 177

8.5.8.1 Servicing the carbon seat post 177

8.5.8.2 by.schulz suspension seat post 178

8.5.8.3 Suntour suspension seat post 178

8.5.8.4 Eightpins NGS2 seat post 179

8.5.8.5 Eightpins H01 seat post 185

8.5.9 Rear frame damper 189

8.5.9.1 FOX component-specific maintenance 190

9 Troubleshooting, fault clearance and repair

9.1 Troubleshooting and fault clearance 191

9.1.1 Drive system or on-board computer does not start up 191

9.1.2 Error message 191

9.1.3 Assistance function errors 192

9.1.4 Battery error 193

9.1.5 On-board computer error 194

9.1.6 Lighting does not work 194

9.1.7 Other drive system errors 195

9.1.8 Suntour suspension fork 196

9.1.8.1 Rebound too fast 196

9.1.8.2 Rebounding too slowly 197

9.1.8.3 Suspension too soft on inclines 198

9.1.8.4 Excessively hard damping on bumps 199

9.1.9 Other errors 200

9.2 Repair 201

9.2.1 Original parts and lubricants 201

9.2.2 Replacing the lighting 201

9.2.3 Setting the front light 201

9.2.4 Checking tyre clearance 201

10 Recycling and disposal

10.1 Removal of waste guidelines 202

11 Documents

11.1 Assembly report 204

11.2 Maintenance log 206

11.3 Parts list 210

11.3.1 Cross Rider EVO 1 210

11.3.2 Cross Rider EVO 2 212

11.4 Charger operating instructions 214

12 Glossary

12.1 Abbreviations 226

12.2 Simplified terms 226

13 Appendix

I. Translation of the original EC/EU Declaration of Conformity 227

II. Declaration of conformity for incomplete machine 228

14 Keyword index

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MY22B01 - 12_1.0_26.08.2021 9

About these operating instructions

Thank you for your trust!

BULLS pedelecs are premium quality vehicles.

You have made an excellent choice. Your

specialist dealer will provide you with guidance

and instruction and assemble your product. Your

specialist dealer will also be happy to assist you in

the future, whether you require maintenance,

conversion or repair.

You are receiving these operating instructions

with your new pedelec. Please take time to

become familiar with your new pedelec. Use the

tips and suggestions in the operating instructions.

They will help you to enjoy your pedelec for a long

time to come. We hope you have fun and wish you

well on all of your rides!

Download the operating instructions onto your

phone at the following link, so that you can use

them when you are out riding:

www.bulls.de/service/downloads.

Distribution or reproduction of these operating

instructions and utilisation or communication of

their content is prohibited unless expressly

approved. Any infringement will render the

offender liable for compensation. All rights

reserved in the event that a patent, utility model or

industrial design is registered.

Subject to internal changes

The information contained in these operating

instructions are the approved technical

specifications at the time of printing. In addition to

the functions described here, software changes

may be introduced to rectify errors and extend

functions at any time.

Any significant changes are included in a new

published version of the operating instructions.

All changes to the operating instructions are

published on the following website:

www.bulls.de/service/downloads.

Editing

Text and images:

ZEG Zweirad-Einkaufs-Genossenschaft eG

Longericher Strasse 2

50739 Köln, Germany

Translation

RKT Übersetzungs- und Dokumentations-GmbH

Bahnhofstrasse 27

78713 Schramberg, Germany

In case of any questions or problems

regarding these operating instructions,

please contact:

tecd[email protected]

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