Bosch ZEMO SU-E FS 12 Verdrahtungsschema

MY22Z0a - 12_1.0_25.07.2022

22-15-2061...22-15-2066

SU-E FS 12 +, ZE 12 +, ZE FS 12 +

Translation of original operating instructions for

ZEMO pedelecs with BOSCH LED Remote

on-board computer

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP SAFE TO CONSULT AT A LATER DATE

MY22Z0a - 12_1.0_25.07.2022 1

Contents

1 About these operating instructions

1.1 Manufacturer 12

1.2 Laws, standards and directives 12

1.3 Language 12

1.4 For your information 12

1.4.1 Warnings 12

1.4.2 Markups 12

1.5 Aim of the operating instructions 13

1.6 Type number and model 14

1.7 Frame number 14

1.8 Identifying the operating instructions 14

2 Safety

2.1 Residual risk 15

2.1.1 Risk of fire and explosion 15

2.1.2 Electric shock 17

2.1.3 Risk of a crash 17

2.1.4 Risk of amputation 17

2.1.5 Key breaking off 17

2.1.6 Malfunctions due to Bluetooth® 18

2.1.7 Data privacy information 18

2.2 Toxic substances 19

2.2.1 Toxic substances 19

2.2.2 Irritants and corrosive substances 19

2.3 Requirements for the rider 19

2.4 Vulnerable groups 19

2.5 Personal protective equipment 20

2.6 Safety guards 20

2.7 Safety markings and safety instructions 20

2.8 What to do in an emergency 21

2.8.1 Dangerous situation in road traffic 21

2.8.2 Leaked brake fluid 21

2.8.3 Battery vapour emission 21

2.8.4 Battery fire 22

3 Description

3.1 Proper use 23

3.1.1 Improper use 24

3.1.2 Permitted total weight (PTW) 25

3.1.3 Environmental requirements 26

3.2 Nameplate 28

3.3 Components 29

3.3.1 Overview 29

3.3.2 Wheel 30

3.3.2.1 Tyres 30

3.3.2.2 Tube-type tyre 30

3.3.2.3 Rim 33

3.3.2.4 Valve 33

3.3.2.5 Spoke 33

3.3.2.6 Spoke nipples 33

3.3.2.7 Hub 34

3.3.3 Chassis 35

3.3.3.1 Frame 35

3.3.3.2 Steering system 35

3.3.3.3 Steering headset 35

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Contents

3.3.3.4 Stem 35

3.3.3.5 Handlebars 36

3.3.3.6 Fork 36

3.3.4 Suspension 37

3.3.4.1 Rigid fork 37

3.3.4.2 Suspension fork 37

3.3.4.3 Rear frame damper 41

3.3.4.4 RockShox rear frame damper 43

3.3.5 Saddle 45

3.3.6 Seat post 45

3.3.6.1 Patent seat post 45

3.3.6.2 Suspension seat post 46

3.3.7 Design of by.Schulz G2 47

3.3.8 Braking system 48

3.3.8.1 Mechanical brake 48

3.3.8.2 Hydraulic brake 48

3.3.8.3 Disc brake 49

3.3.9 Mechanical drive system 50

3.3.9.1 Chain drive layout 50

3.3.9.2 Belt drive layout 50

3.3.10 Electric drive system 51

3.3.10.1 Motor 51

3.3.10.2 Rechargeable battery 51

3.3.10.3 Charger 52

3.3.10.4 Lighting 52

3.3.10.5 Integrated battery 52

3.3.11 On-board computer 53

3.4 Description of controls and screens 54

3.4.1 Handlebars 54

3.4.2 Control panel 55

3.4.2.1 System message 56

3.4.2.2 Creating a user account 57

3.4.2.3 Software updates 57

3.4.2.4 Activity tracking 57

3.4.2.5 Lock function 57

3.4.3 Battery level indicator (battery) 58

3.4.4 Gear shift 59

3.4.4.1 SHIMANO SW-E7000 derailleur gears 59

3.4.5 SHIMANO gear shift 60

3.4.5.1 3-switch switch control panel 60

3.4.5.2 2-switch switch control panel 60

3.4.5.3 MTB switch control panel 60

3.4.5.4 Switch control panel functions on right 60

3.4.5.5 Shifter SL-M5100 60

3.4.5.6 Shifter SL-M8100 61

3.4.6 Fork lock 62

3.4.6.1 SR Suntour 62

3.4.7 Handbrake 63

3.5 Technical data 64

3.5.1 Pedelec 64

3.5.2 Emissions 64

3.5.3 Bicycle lighting 64

3.5.4 Display mount 64

3.5.5 LED Remote on-board computer 64

3.5.6 BOSCH Performance Line CX motor 64

3.5.7 BOSCH PowerTube 750 battery 65

3.5.8 Saddle width 66

3.5.8.1 BROOKS ENGLAND 66

3.5.8.2 ERGON 66

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Contents

3.5.8.3 SELLE ROYAL 66

3.5.9 Puncture protection level 67

3.5.9.1 SCHWALBE 67

3.5.10 Torque 68

4 Transporting and storing

4.1 Weight and dimensions for transportation 75

4.2 Designated handles, lifting points 77

4.3 Transporting 78

4.3.1 Using the transport securing system 78

4.3.2 Transporting the pedelec 78

4.3.3 Shipping a pedelec 78

4.3.4 Transporting the battery 78

4.3.5 Shipping the battery 78

4.4 Storing 79

4.4.1 Pedelec 79

4.4.2 On-board computer, display and charger 79

4.4.3 Rechargeable battery 79

4.4.4 Break in operation 80

4.4.4.1 Preparing a break in operation 81

4.4.4.2 Carrying out a break in operation 81

5 Assembly

5.1 Unpacking 82

5.2 Required tools 82

5.3 Commissioning 83

5.3.1 Checking the battery 83

5.3.1.1 Securing the PowerTube BS3 battery mount 84

5.3.2 Preparing the wheel 89

5.3.3 Installing the wheel in the SUNTOUR fork 90

5.3.3.1 Screw-on axle (12AH2 and 15AH2) 90

5.3.3.2 20 mm cross axle 91

5.3.3.3 Q-LOC quick release 93

5.3.4 Fitting the pedals 94

5.3.5 Preparing the LIMOTEC seat post 95

5.3.6 Checking the stem and handlebars 96

5.3.6.1 Checking the connections 96

5.3.6.2 Checking stem is firmly in position 96

5.3.6.3 Checking the bearing clearance 96

5.4 Selling the pedelec 96

6 Operation

6.1 Risks and hazards 97

6.2 Tips for a greater range 99

6.3 Error message 100

6.3.1 On-board computer 100

6.3.1.1 Less critical errors 100

6.3.1.2 Critical errors 100

6.3.2 Rechargeable battery 100

6.4 Instruction and customer service 101

6.5 Adjusting the pedelec 101

6.5.1 Preparing 101

6.5.2 Pedelec adjustment procedure 102

6.5.3 Saddle 103

6.5.3.1 Replacing the saddle 103

6.5.3.2 Determining saddle shape 103

6.5.3.3 Determining minimum saddle width with corrugated cardboard 105

6.5.3.4 Determining minimum saddle width with gel cushion 105

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Contents

6.5.3.5 Calculating the saddle width 106

6.5.3.6 Selecting the saddle hardness 106

6.5.3.7 Adjusting the saddle hardness 106

6.5.3.8 Straighten saddle 106

6.5.3.9 Positioning the saddle with eightpins suspension seat post 106

6.5.3.10 Adjusting the saddle height 107

6.5.3.11 Setting the saddle height with the remote control 108

6.5.4 Riding position 109

6.5.4.1 Straighten saddle 111

6.5.4.2 Positioning the saddle with eightpins suspension seat post 111

6.5.4.3 Adjusting the saddle height 112

6.5.4.4 Setting the saddle height with the remote control 113

6.5.4.5 Adjusting the saddle position 114

6.5.4.6 Adjusting the saddle tilt 114

6.5.4.7 Checking saddle stability 114

6.5.5 Handlebars 115

6.5.5.1 Replace handlebars 115

6.5.5.2 Adjusting the handlebar width 115

6.5.5.3 Adjusting the hand position 115

6.5.5.4 Adjusting the handlebars 116

6.5.6 Stem 117

6.5.6.1 Replacing the handlebars 117

6.5.6.2 Adjusting the handlebar height with quick release 117

6.5.6.3 Checking the stem stability 117

6.5.6.4 Adjusting the quick release clamping force 117

6.5.6.5 Setting the quill stem 118

6.5.6.6 Adjusting the Ahead stem 118

6.5.6.7 Adjusting the angle-adjustable stem 119

6.5.7 Handles 120

6.5.7.1 Replacing the handles 120

6.5.7.2 Adjusting ergonomic handles 120

6.5.7.3 Checking handlebar stability 120

6.5.8 Tyres 121

6.5.8.1 Adjust tyre pressure 121

6.5.9 Brake 122

6.5.9.1 Change handbrake position 122

6.5.9.2 Change handbrake inclination angle 122

6.5.9.3 Determining the grip distance 123

6.5.9.4 Replacing brakes 124

6.5.9.5 Retracting the brake linings 124

6.5.9.6 Grip distance on a SHIMANO ST-EF41 brake lever 125

6.5.9.7 Grip distance on a SHIMANO ST-EF41 handbrake 126

6.5.10 Tyres 127

6.5.10.1 Adjust tyre pressure 127

6.5.10.2 Replacing tyres 128

6.5.11 Gear shift 129

6.5.11.1 Replacing the gear shift 129

6.5.11.2 Adjusting the SHIMANO shifter 129

6.5.12 Suspension 130

6.5.13 Fork sag 130

6.5.13.1 Adjusting the SR SUNTOUR fork steel suspension 131

6.5.13.2 Adjusting the SR SUNTOUR fork air suspension 132

6.5.13.3 ROCKSHOX Paragon Silver coil spring 133

6.5.13.4 Adjusting the RockShox coil spring with an external preload adjuster 135

6.5.13.5 Adjusting the ROCKSHOX fork coil spring with spacer for pre-tensioning 136

6.5.14 Adjust the rear frame damper sag 138

6.5.14.1 Adjusting the Suntour rear frame damper 139

6.5.14.2 Adjusting the RockShox rear frame damper 140

6.5.15 Fork rebound damping 142

MY22Z0a - 12_1.0_25.07.2022 5

Contents

6.5.15.1 Adjusting the SR SUNTOUR fork rebound damping 143

6.5.15.2 Adjusting the RockShox suspension fork 144

6.5.16 Adjusting the rear frame damper rebound damper 145

6.5.16.1 Adjusting the RockShox rear frame damper 146

6.5.17 Compression adjuster on rear frame damper 147

6.5.17.1 Adjusting the Suntour compression adjuster 148

6.5.17.2 Adjusting the RockShox compression adjuster 149

6.5.17.3 Adjusting the RockShox threshold 150

6.5.18 Riding light 151

6.5.18.1 Adjusting the headlight 152

6.5.19 On-board computer 153

6.5.19.1 Creating a user account 153

6.5.19.2 Connecting the on-board computer to a smartphone 153

6.5.19.3 Update software 153

6.5.19.4 Activating activity tracking 153

6.5.19.5 Setting up the lock function (optional) 153

6.6 Accessories 155

6.6.1 Child seat 155

6.6.2 Trailer 156

6.6.2.1 Approval for trailer with Enviolo hub 156

6.6.2.2 Approval for trailer with ROHLOFF hub 157

6.6.3 Mobile holder 157

6.6.4 Tubeless and airless tyres 157

6.6.5 Suspension fork coil spring 157

6.6.6 Pannier rack 158

6.6.7 Panniers and cargo boxes 158

6.7 Personal protective equipment and accessories for road safety 159

6.8 Before each ride 159

6.9 Straightening the quickly adjustable stem 160

6.10 Using the pannier rack 160

6.11 Raising the kickstand 161

6.12 Using the saddle 161

6.12.1 Using the leather saddle 161

6.13 Using the pedals 161

6.14 Using the bell 161

6.15 Using the handlebars 162

6.15.1 Using multi-position handlebars 162

6.15.2 Using bar ends 162

6.15.3 Using leather handles 162

6.16 Using the battery 163

6.16.1 Removing the battery 163

6.16.1.1 Inserting the battery 163

6.16.2 Charging the battery 164

6.17 Using pedelec with the electric drive system 165

6.17.1 Switching on the electric drive system 165

6.17.2 Switching off the electric drive system 165

6.18 Using the on-board computer 166

6.18.1 Using the diagnosis port 166

6.18.2 Charging the control panel battery 166

6.18.3 Using the riding light 167

6.18.4 Setting the brightness of indicators 167

6.18.5 Using the push assist system 167

6.18.6 Selecting the level of assistance 168

6.19 Brake 169

6.19.1 Using the brake lever 169

6.20 Gear shift 170

6.20.1 Using the derailleur gears 170

6.21 Use suspension and damping 171

6.21.1 Adjusting the SR SUNTOUR compression adjuster 172

MY22Z0a - 12_1.0_25.07.2022 6

Contents

6.21.1.1 Adjusting the RockShox compression adjuster 173

6.22 Parking the pedelec 174

6.22.1 Screwing in the quickly adjustable stem 175

6.22.2 Activating the lock function 176

7 Cleaning, servicing and inspection

7.1 Before each ride 181

7.1.1 Checking the guards 181

7.1.2 Checking the frame 181

7.1.3 Checking the fork 181

7.1.4 Checking the rear frame damper 181

7.1.5 Checking the pannier rack 181

7.1.6 Checking the mudguards 181

7.1.7 Check wheel concentricity 181

7.1.8 Checking the quick releases 181

7.1.9 Checking the suspension seat post 182

7.1.10 Checking the bell 182

7.1.11 Checking the handles 182

7.1.12 Checking the USB cover 182

7.1.13 Checking the riding light 182

7.1.14 Checking the brake 182

7.2 After each ride 183

7.2.1 Cleaning the riding light and reflectors 183

7.2.2 Cleaning the suspension fork 183

7.2.3 Caring for the suspension fork 183

7.2.4 Cleaning the pedals 183

7.2.5 Cleaning the brake 183

7.2.6 Cleaning the suspension seat post 183

7.2.7 Cleaning the rear frame damper 183

7.3 Basic cleaning 184

7.3.1 Clean on-board computer and control panel 184

7.3.2 Cleaning the battery 184

7.3.3 Cleaning the motor 184

7.3.4 Clean Frame, fork, pannier rack, guards and kickstand 185

7.3.5 Cleaning the stem 185

7.3.6 Cleaning the handlebars 185

7.3.7 Clean handles 185

7.3.7.1 Cleaning leather handles 185

7.3.8 Clean seat post 185

7.3.9 Cleaning the saddle 186

7.3.9.1 Cleaning the leather saddle 186

7.3.10 Cleaning the tyres 186

7.3.11 Cleaning the spokes and spoke nipples 186

7.3.12 Clean hub 186

7.3.13 Cleaning the switching elements 186

7.3.13.1 Cleaning the shifter 186

7.3.14 Clean cassette, chain wheels and front derailleur 186

7.3.15 Clean brake 187

7.3.15.1 Clean handbrake 187

7.3.16 Cleaning the brake disc 187

7.3.17 Cleaning the belt 187

7.3.18 Cleaning the chain 187

7.3.18.1 Clean chain, including all-round chain guard 187

7.4 Servicing 188

7.4.1 Frame 188

7.4.2 Fork 188

7.4.3 Pannier rack 189

7.4.4 Mudguard 189

7.4.5 Servicing the kickstand 189

MY22Z0a - 12_1.0_25.07.2022 7

Contents

7.4.6 Stem 189

7.4.7 Handlebars 189

7.4.8 Handle 189

7.4.8.1 Rubber handles 189

7.4.8.2 Leather handle 189

7.4.9 Seat post 190

7.4.9.1 Suspension seat post 190

7.4.9.2 Carbon seat post 190

7.4.10 Rim 190

7.4.11 Leather saddle 190

7.4.12 Hub 190

7.4.13 Spoke nipples 190

7.4.14 Gear shift 191

7.4.14.1 Rear derailleur articulated shafts and jockey wheels 191

7.4.14.2 Shifter 191

7.4.15 Pedal 191

7.4.16 Caring for the chain 191

7.4.16.1 Caring for the chain and all-round chain guard 192

7.4.17 Caring for the battery 192

7.4.18 Caring for the brake 192

7.4.18.1 Caring for handbrake 192

7.4.19 Lubricating the Eightpins seat post tube 192

7.5 Inspection 193

7.5.1 Checking the wheel 193

7.5.1.1 Checking tyre pressure 193

7.5.1.2 Checking the tyres 195

7.5.1.3 Checking the rims 196

7.5.1.4 Checking the nipple holes 196

7.5.1.5 Checking the nipple well 196

7.5.1.6 Checking the rim hooks 196

7.5.1.7 Checking the spokes 196

7.5.2 Checking the brake system 197

7.5.2.1 Checking the handbrake 197

7.5.2.2 Checking the hydraulic brake system 197

7.5.2.3 Checking the Bowden cables 197

7.5.2.4 Checking the disc brake 198

7.5.2.5 Checking the back-pedal brake 199

7.5.2.6 Checking the rim brake 200

7.5.3 Checking the chain 201

7.5.4 Checking the chain tension 201

7.5.4.1 Check tension in derailleur gears 201

7.5.4.2 Check tension in hub gear 201

7.5.5 Checking the belt for wear 201

7.5.5.1 Rough check 201

7.5.5.2 Check 202

7.5.6 Checking the belt 203

7.5.7 Checking the belt for wear 203

7.5.8 Checking the belt sprockets for wear 203

7.5.9 Check belt tension 203

7.5.9.1 Gates Carbon Drive mobile app 204

7.5.9.2 Gates Krikit tension meter 204

7.5.9.3 ECO tension tester 205

7.5.10 Checking the riding light 206

7.5.11 Checking the stem 207

7.5.12 Checking the handlebars 207

7.5.13 Checking the saddle 207

7.5.14 Checking the seat post 207

7.5.14.1 Checking the derailleur gears 207

7.5.14.2 Checking the hub gear 208

MY22Z0a - 12_1.0_25.07.2022 8

Contents

7.5.15 Check gear shift 208

7.5.15.1 Electric gear shift 208

7.5.15.2 Mechanical gear shift 208

7.5.15.3 Checking the derailleur gears 209

7.5.16 Adjusting gear shift 209

7.5.16.1 Adjusting the ROHLOFF hub 209

7.5.17 Adjusting cable-operated gear shift, dual-cable 209

7.5.18 Adjusting Bowden-cable-operated twist grip, dual-cable 210

7.5.19 Checking kickstand stability 210

8 Inspection and maintenance

8.1 Initial inspection 211

8.2 Major inspection 211

8.3 Component-specific maintenance 211

8.4 Carry out initial inspection 214

8.5 Inspection and maintenance instructions 215

8.5.1 Inspecting the frame 222

8.5.1.1 Inspect the carbon frame 222

8.5.2 Inspecting the pannier rack 222

8.5.3 Inspect and maintain rear frame damper 222

8.5.4 Inspect gear hub 223

8.5.4.1 Adjusting the hub with cone bearing 223

8.5.5 Inspecting the stem 223

8.5.6 Inspect and grease steering headset 223

8.5.7 Inspecting axle with quick release 224

8.5.8 Inspecting the fork 225

8.5.8.1 Inspect the carbon suspension fork 225

8.5.8.2 Inspect the suspension fork 225

8.5.9 Inspecting the seat post 226

8.5.9.1 Inspect carbon seat post 226

8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post 227

8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post 227

9 Troubleshooting, fault clearance and repair

9.1 Preventing pain 228

9.1.1 Sitting discomfort 229

9.1.2 Pain in hips 229

9.1.3 Backache 229

9.1.4 Pain in shoulders and nape of neck 230

9.1.5 Numb or aching hands 230

9.1.6 Pain in upper thigh 230

9.1.7 Knee pain 231

9.1.8 Pain in the foot 231

9 Troubleshooting, fault clearance and repair

9.1 Troubleshooting and fault clearance 232

9.1.1 Drive system or on-board computer does not start up 232

9.1.2 Errors in assistance function 233

9.1.3 Battery errors 234

9.1.4 Errors on the control panel 235

9.1.5 Lighting does not work 235

9 Troubleshooting, fault clearance and repair

9.1 Troubleshooting and fault clearance 236

9.1.1 Drive system or on-board computer does not start up 236

9.1.2 Error message 236

9.1.3 Assistance function errors 237

9.1.4 Battery error 238

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Contents

9.1.5 On-board computer error 239

9.1.6 Lighting does not work 239

9.1.7 Problems with freewheel 240

9.1.8 Problems with hub gear 241

9.1.9 Problems with disc brakes 243

9.1.10 Problems with rim brakes 244

9.1.11 Problems with back-pedal brake 245

9.1.12 Other errors 246

9.1.13 SR SUNTOUR suspension fork 247

9.1.13.1 Rebound too fast 247

9.1.13.2 Rebounding too slowly 248

9.1.13.3 Suspension too soft on inclines 249

9.1.13.4 Excessively hard damping on bumps 250

9.1.14 RockShox suspension fork 251

9.1.14.1 Rebound too fast 251

9.1.14.2 Rebounding too slowly 252

9.1.14.3 Suspension too soft on inclines 253

9.1.14.4 Excessively hard damping on bumps 254

9.1.15 Rear frame damper 255

9.1.15.1 Rebound too fast 255

9.1.15.2 Rebounding too slowly 256

9.1.15.3 Suspension too soft on inclines 257

9.1.15.4 Excessively hard damping on bumps 258

9.1.16 RockShox rear frame damper 259

9.1.16.1 Rebound too fast 259

9.1.16.2 Rebounding too slowly 260

9.1.16.3 Suspension too soft on inclines 261

9.1.16.4 Excessively hard damping on bumps 262

9.2 Repair 263

9.2.1 Original parts and lubricants 263

9.2.2 Repairing the frame 263

9.2.2.1 Removing paint damage on frame 263

9.2.2.2 Removing damage from impact on the carbon frame 263

9.2.3 Repairing the suspension fork 263

9.2.3.1 Removing paint damage on the fork 263

9.2.3.2 Removing damage from impact on the carbon frame 263

9.2.3.3 Repairing the seat post 263

9.2.3.4 Repairing damage from impact on the carbon post seat post 263

9.2.4 Replacing the riding light 264

9.2.5 Adjusting the headlight 264

9.2.6 Checking suspension fork-tyre clearance 264

9.2.7 Replacing pedelec components if lock function is installed 265

9.2.7.1 Replacing a smartphone 265

9.2.7.2 Replacing the on-board computer 265

9.2.7.3 Activating the lock function after motor replacement 265

10 Recycling and disposal

10.1 Guidelines on removal of waste 266

11 Documents

11.1 Assembly report 268

11.2 Inspection and maintenance log 270

11.3 Parts list 274

11.3.1 SU-E FS 12 274

11.3.2 ZE 12+ 276

11.3.3 ZE FS 12+ 278

11.4 Charger operating instructions 280

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