The provided document is the "Original Operational Instructions" for the PIVOT SHUTTLE AM e-bike, featuring a BOSCH ePowered system.
Function Description
The PIVOT SHUTTLE AM is an electric mountain bike designed for off-road use. This manual provides comprehensive information for setting up, operating, and maintaining the bike, including its Bosch E-bike System. It covers suspension and tire setup, system operation, system information, schematics, and additional safety guidelines for both the bicycle and its battery. The e-bike system offers various levels of assistance, walk assist, and can be customized via a smartphone app.
Important Technical Specifications
Suspension/Tire Setup:
- Shock Air Pressure (by Body Weight):
- [kg] to [bar]: 0.15 × Body Weight [kg] + 2 [bar]
- [kg] to [psi]: 2.2 × Body Weight [kg] + 30 [psi]
- [lbs] to [bar]: 0.07 × Body Weight [lbs] + 2 [bar]
- [lbs] to [psi]: Body Weight [lbs] + 30 [psi]
- Shock Compression Damping: 8 clicks in from OPEN (Note: Not available on all builds).
- Shock Rebound Damping: 6 clicks in from OPEN.
- Fork Air Pressure: 80 [psi] / 5.52 [bar].
- Fork Compression Damping: HSC: 2 clicks in from OPEN*; LSC: 5 clicks in from OPEN (Note: Not available on all builds).
- Fork Rebound Damping: HSR: 3 clicks in from OPEN*; LSR: 7 clicks in from OPEN (Note: Not available on all builds).
- Front Tire Pressure: 23 [psi] / 1.58 [bar].
- Rear Tire Pressure: 28 [psi] / 1.93 [bar].
- Fox Float X Rebound Damping: Settings vary based on air pressure, ranging from 1 click in from OPEN (<120 psi) to CLOSED (280-300 psi).
- Fox 36 Forks Sag: Recommended between 15% and 20% of total fork travel (24.0 - 32.0mm for a 160mm fork).
- Fox 36 Forks Air Pressure: Should not exceed 8.3 [bar] (120 [psi]). Rider weight chart provided for initial settings (e.g., 55-59 kg / 120-130 lbs = 58 psi / 4.0 bar).
- Fox 36 Grip 2 Forks Compression Damping: Black (LSC) dial clockwise 5 clicks, blue (HSC) dial clockwise 2 clicks for a good starting point.
- Fox 36 Grip Forks Compression Damping: Lever in full open position for most riders. Halfway turned provides low-speed compression adjustment. Fully closed provides a nearly locked-out feel.
- Fox 36 Forks Rebound Damping: Settings vary based on rider weight, with LSR/HSR clicks from OPEN provided (e.g., 120-130 lbs = 3/Open).
- Recommended Tire Pressure: Front: 1.58 [bar] / 23 [psi]; Rear: 1.93 [bar] / 28 [psi].
Bosch Drive System Components (Schematic):
- Mini Remote: EB13.100.001
- System Controller: EB13.100.000
- Batteries: PowerTube 750 (US, CAN, JP, KOR: EB12.100.0OZ; EU28, CH, NO, AUS, NZ: EB12.100.00X), PowerTube 625 (Ride Level Builds US, CAN, JP, KOR: EB12.100.013; EU28, CH, NO, AUS, NZ: EB12.100.011)
- Rim Magnet (Speed Sensor): EB11.200.015
- Spider & Chainring: ES-BSC-104-565-34T (Ride Builds), ES-BSC-104-565/00.6218.034.003 (Pro/Team Builds)
- Drive Unit Lockring & O-Ring: 1270.014.085/1270.016.119
- Crank Arms: EC-1ISIS-160A (Ride/Pro Builds), EC-1ISIS-160CM (Team Builds)
- Drive Unit: CX Performance (EB11.100.000), CX Performance Race Edition (EB11.100.00G)
- Charging Socket & Cable: EB12.120.048
- Charging Socket Cover: EB12.120.01B
- Battery Chargers: 4A110V/Cable (US: EB12.110.000/1270.020.343), 4A 230V/Cable (EU: EB12.110.001/1270.020.330), 4A 230V/Cable (AUS: EB12.110.001/1270.020.344), 4A 230V/Cable (UK: EB12.110.001/1270.020.331)
- Rear Axle: 157MM THROUGH AXLE V5 (15 Nm / 11 lb·ft torque).
Hardware Torques:
- Universal Rear Derailleur Hanger Bolt: 25 Nm (18 lb·ft)
- M8 Front Shock Bolt: 13 Nm (10 lb·ft)
- M14x20 Link Bolt: 35 Nm (27 lb·ft)
- M10 Trunnion Mount Bolt: 13 Nm (10 lb·ft)
- M14x20 Flip Chip Bolt: 35 Nm (27 lb·ft)
- M5x6 DT Water Bottle Bolts: 3 Nm (26 in-lb)
- M8x18 Socket Head Screw (Top Tube Tool Bolts): 13 Nm (10 lb·ft)
- M6x14 Front Bracket/Skid Plate Bolts: 6 Nm (53 in-lb)
- M6x16 Rear Bracket Bolts: 6 Nm (53 in-lb)
- Battery Mounting Bolts: 1 Nm (9 in-lb)
- Grease (Bolt Shaft) Thread Locker (Bolt Threads): 25 Nm (18 lb·ft)
Usage Features
- Quick Start Guide: Provides essential setup information for suspension, tire pressure, saddle height adjustment, battery charging, and system power on/off.
- Adjusting Saddle Height: Uses a 2mm hex wrench for the dropper post housing and a 4mm hex wrench for the seat post clamp bolt. Torque for seat post clamp bolt is 5 Nm.
- Powering System ON/OFF: A quick press and release on the power symbol on the system controller. Automatic shut-off after 10 minutes of inactivity.
- Adjusting Levels of Assistance: Can be done via the Mini Remote (+/- buttons) or the System Controller (mode button). Five assist levels are indicated by LED colors: LED OFF (motor off), GREEN (effective support), BLUE (steady support), PURPLE (optimal support), RED (maximum support). Walk assist is also available.
- Battery Charge Indicator: LEDs on the System Controller indicate charge status (ice-blue bars for 20% capacity, white for 10%). Lower bars change color (orange for 30-11%, red for 10% to reserve, flashing red for reserve to empty).
- Smartphone Connection: Requires the Bosch eBike Flow app for additional functions.
- Mini Remote Connection: Connects to the System Controller via Bluetooth®. Instructions provided for pairing new devices through the app.
- Rim Magnet Speed Sensor: Replaces traditional rotor magnets, detected by the drive unit for speed calculation. Requires a tube with at least a 32mm long valve stem for mounting.
- Riding Mode Customization: eBike Flow App allows fine-tuning of riding modes for support and power consumption.
- Display Options: Bosch offers various display options and mounts, including using a smartphone as a display via the eBike Flow App.
- eBike Lock: A feature activated through the eBike Flow App that disables assist and uses the smartphone as a key.
- ConnectModule: Optional unit (dealer-installed) providing an audible alarm, message alerts for bike movement, and GPS tracking.
- System Updates: Firmware updates can be installed via the eBike Flow App or by a Pivot Dealer.
Maintenance Features
- Battery Charging: Battery must be fully charged before first use. Charging port is on the non-drive side of the frame. System controller illuminates to display charging status. Battery is fixed in the frame and should only be removed by an authorized dealer.
- Error Messages: The control unit displays critical (flashing red LED) and less critical (flashing orange LED) errors. Error codes can be read via the eBike Flow app or by a Pivot dealer. Suggestions for less critical errors include checking the speed sensor for interference. Critical errors require contacting a Pivot dealer.
- Bicycle Safety: The bike is designed for off-road use, not public roads unless legally equipped. Emphasizes adherence to operating, service, and repair conditions.
- Battery Safety:
- Refer to the Bosch battery manual for safety and care.
- Adhere to dangerous goods regulations for transport.
- Do not charge, use, or transport damaged batteries.
- Avoid submerging batteries in water.
- Use only the supplied charger.
- Keep batteries and charger out of reach of children.
- Charge in dry rooms with smoke/fire detectors, on a non-inflammable surface.
- Keep away from moisture during charging.
- Do not expose to blazing sun.
- Do not steam clean, high-pressure clean, or clean with a water hose. Clean with a soft rag and neutral detergents.
- Inspect battery for damage (cracks, breakages, discolorations) and contact dealer if found.
- Battery Recycling Information: Pivot is a partner of Call2Recycle battery recycling program.
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