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Kalkhoff Pedelec Xion

Kalkhoff Pedelec Xion
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Original User Manual
English
Derby Cycle Werke GmbH 2013* Not included in this document.
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Table of Contents

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Kalkhoff Pedelec Xion Specifications

General IconGeneral
BrandKalkhoff
ModelPedelec Xion
CategoryBicycle
LanguageEnglish

Summary

The Bike and Its Components

Preface

Repairing a Puncture

Opening the Brake

Details on how to open different types of bicycle brakes (cantilever, V-brake, hydraulic rim, side-pull caliper).

Removing the Wheel

Instructions for removing the front and rear wheels from the bike frame.

Bike Gears

Derailleur Gears

Explanation of the handling and operation of derailleur gears for various bike types.

Hub Gears

Information on hub gear systems for city and trekking bikes, including operation.

Safety Information

Basic Safety Information

Essential safety guidelines and information for all users of the manual.

For Your Own Safety

Recommendations for personal safety while riding, including helmet and clothing.

Safety in Road Traffic

Rules and advice for safe cycling in road traffic, including regulations and behavior.

Bike Safety

Important safety aspects related to the bike's components and usage, including weight limits.

Legal Provisions

Applicable Road Traffic Licensing Regulations

Details on national regulations and licensing requirements for using bicycles in road traffic.

Intended Use

General Information

General information on the intended use of bicycles, including limitations and responsibilities.

Trekking Bike All-Terrain Bike (ATB)

Specifies the intended use for trekking and ATB bikes, including road and gentle off-road conditions.

City, Touring, Sports, Childs and Youngsters Bike

Outlines the intended use for city, touring, sports, and youth bicycles on roads and surfaced routes.

Mountain Bike (MTB) Cross Bike

Details the intended use for MTB and cross bikes, primarily off-road, with road use limitations.

Road Bike Fitness Bike

Defines the intended use for road and fitness bikes, suitable for public roads and training.

BMX

Specifies the intended use for BMX bikes, focusing on BMX routes and practice facilities.

Before the First Ride

Before Every Ride

Setting Up the Bike for the Rider

Fitting the Pedals

Instructions for correctly fitting the pedals to the bike's crank arms, noting thread types.

Adjusting the Seat Position

Guidance on adjusting the bike saddle for optimal comfort and position.

Determining the Correct Saddle Height

Adjusting the Saddle Angle

With a Two-Bolt Seatpost

Details on adjusting saddle angle using a two-bolt seatpost mechanism.

With a Seatpost Saddle Clamp

Instructions for adjusting saddle angle with a seatpost saddle clamp.

With a Suspension Seatpost

Adjusting the Handlebar Position

Adjusting Aligning the Handlebar Height with a Conventional Handlebar Stem

Steps for adjusting handlebar height using a conventional stem and Allen key.

Adjusting the Handlebar Height with A-head Systems

Guidance on adjusting handlebar height for bikes with A-head stem systems.

Aligning Handlebars with A-head Systems in Relation to the Front Wheel

Procedure for aligning handlebars correctly with the front wheel on A-head systems.

Adjusting the Handlebar Position by Turning the Handlebar

Instructions on adjusting handlebar position by rotating it in the stem for comfort.

Adjusting the Handlebar Height with an Adjustable Handlebar Stem

Steps for adjusting handlebar height and tilt with an adjustable handlebar stem.

Frame

Headset

Fork

Suspension Frame and Suspension Elements

Frame with Rear Suspension

Explanation of full-suspension frames, rear triangles, and shock absorbers.

Care and Maintenance

Guidelines for cleaning and maintaining full-suspension MTBs and suspension elements.

Bottom Bracket and Cranks

Checking the Bottom Bracket

Wheels

Checking the Wheels

Guidance on checking wheels, spokes, and truing after initial rides and regular checks.

Checking the Hubs

Steps for checking hub bearings for smooth rotation and play.

Checking the Rims

Tyres and Inner Tubes

Tyres

Details on tyre types, tread profiles, inflation pressures, and replacement.

Tubeless Tyres

Information on the use and handling of tubeless tyres and rims.

Tubed Tyres

Details on tubed tyres, their construction, and recommendations for professional replacement.

Inner Tubes

Overview of different inner tube valve types: Sclaverand, Schrader, and Dunlop.

Repairing a Puncture

Opening the Brake

Instructions for opening different types of bicycle brakes (cantilever, V-brake, hydraulic rim, side-pull caliper).

Removing the Wheel

Step-by-step guide for removing the front and rear wheels, including specific instructions for different gear systems.

Removing the Tyre and Inner Tube

Procedure for safely removing the tyre and inner tube from the rim.

Mending the Inner Tube

Instructions for locating and patching a puncture in an inner tube using a repair kit.

Fitting the Tyre and Inner Tube

Steps for correctly fitting the tyre and inner tube back onto the rim, ensuring proper seating.

Fitting the Wheel

Instructions for refitting the front and rear wheels, including chain and brake considerations.

Bike Gears

Derailleur Gears

Explanation of how to operate derailleur gears for various bike types, including maintenance advice.

Hub Gears

Information on hub gears used in city and trekking bikes, including operation.

Operating the Shifting Lever

Shifting Lever on Road Bike

Detailed instructions on operating the shifting lever for road bikes, illustrating lever functions.

Operating the Rear Derailleur Shifting Lever

Operating the Front Derailleur Lever (standard)

Operating the Front Derailleur Lever with Trimming (Noise Prevention), Optional

Trimming (Noise Prevention)

Description of the trimming process to eliminate chain rub on the front derailleur.

SRAM Shifting Lever

Shifting Lever on MTB, Trekking and Touring Bike

Guide to operating shifting levers for MTB, trekking, and touring bikes.

Shifting from a Large to a Smaller Chainring

Operating the Standard Rear Derailleur Shifting Lever

Twist-Grip Shifters

Rear Derailleur

Precision AdjustmentRear Derailleur

Steps for precise adjustment of rear derailleur gears, including cable tension and screw adjustments.

Hub Gears

Operating the Hub Gears

Instructions for operating Shimano 7/8-speed hub gears and twist-shift levers.

Adjusting Gears with Shimano Hub Gears

Bike Chain

Maintenance of Bike Chains

Guidance on cleaning, lubricating, and checking bike chains for wear.

Brake, Brake Levers and Brake Systems

Important Information and Precautionary Measures

Essential safety information and precautions regarding bicycle brake systems.

Brake Lever

Standard Brake Lever

Information on standard brake levers, including checking lever pull and pad adjustment.

Hub Brakes

Drum and Roller Brakes

Overview of drum and roller hub brakes, their maintenance, and operation.

Back-pedal Brake

Rim Brakes

Readjusting the Brake

Procedure for readjusting rim brakes to ensure proper gap and braking effect.

Adjusting the Brake-Pad Clearance in Relation to the Rim

Steps to adjust the clearance between brake pads and the rim for optimal braking.

Wear of Brake Pad

Disc Brakes

Hydraulic Disc Brake

Explanation of hydraulic disc brake operation, maintenance, and brake testing.

Vapour Bubble Formation

Information on vapour bubble formation in hydraulic brakes and how to address it.

Cleaning the Brake System

Instructions for cleaning hydraulic disc brake systems using specific agents.

FittingRemoving the Wheel

Steps for fitting and removing wheels with disc brakes, including spacer use and lever placement.

Lighting System

Specifications for Lighting System

Technical specifications for front and rear bicycle lights, including beam patterns and distance.

Special Regulations for Road Bikes

Regulations for battery-operated and dynamo lighting systems on road bikes.

GeneratorDynamo

Information on dynamos that generate power for lights, including sidewall dynamo.

Switching the Sidewall Dynamo On and Off

Hub Dynamo

Failure of the Lighting System

Add-on Components

Pannier Rack

Information on pannier racks, load capacities, and proper luggage carrying.

Front Pannier Rack

Details on front pannier racks, their attachment, and effect on steering.

Rear Pannier Rack

Information on rear pannier racks, their attachment, and impact on suspension.

Wheel Guards Mudguards

Details on mudguard struts, their positioning, and safety-release mechanisms.

Re-engaging the Safety-Release Mechanism

Procedure for reattaching mudguard struts to the safety-release mechanism.

Accessories and Equipment

Child Seat

Guidelines for fitting child seats, safety precautions, and weight limits.

Bike Stand

Bike Trailer

Bike Basket

Bar Ends

Bike Carriers for Mounting on Roof and Rear of Car

Carbon Components

Properties

Information on the properties of carbon components and their specific handling requirements.

Torques

Guidance on recommended tightening torques for carbon components, emphasizing lower values.

Visual Inspection

Instructions for visually inspecting carbon components for damage, cracks, or changes.

Carbon Frame

Specific areas of the carbon frame to inspect regularly for cracks or damage.

Carbon Handlebar

Recommendations for inspecting carbon handlebars and the best course of action after a fall.

Carbon Handlebar Stem

Checks for the carbon handlebar stem, especially the clamping area and head tube fit.

Carbon Wheels

Notes on surface wear and braking behaviour of carbon rims.

Carbon Fork

Areas of the carbon fork to inspect for damage, including blades, dropouts, and clamping areas.

Carbon Seatpost

Inspection points for carbon seatposts, including transition areas and screw contact points.

Splinters

Warning about handling damaged carbon parts due to potential splinters and injury.

Fastening in Mounting Stand

Advice on clamping carbon frames in a mounting stand, recommending seatpost clamping.

Transportation by Car

Guidelines for transporting bikes with carbon frames or components by car.

Care and Maintenance of the Bike

Care

General advice on cleaning the bike, avoiding contact with brake parts, and using safe cleaning agents.

Wear Parts

Information that bike parts are subject to wear and require regular checks and replacement.

Tyres

Advice on tyre wear, checking pressure, and avoiding damage from chemicals.

Rims in Conjunction with Rim Brakes

Discussion of wear on rims due to interaction with rim brakes and wear indicators.

Brake Pads

Information on brake pad wear for various brake types and the need for regular checks.

Brake Discs

Details on brake disc wear from intensive braking and replacement advice.

Bike Chains or Toothed Belts

Factors affecting bike chain wear and recommendations for cleaning and lubrication.

Chainrings, Sprocket Wheels and Jockey Wheels

Information on wear of chainrings, sprockets, and jockey wheels in derailleur systems.

Lamps of Lighting Set

Notes on replacement of bulbs and lamps in the lighting set.

Handlebar Tapes and Handle Grips

Information on wear of handlebar tapes and grips and the need for secure seating.

Hydraulic Oils and Lubricants

Importance of replacing hydraulic oils and lubricants to prevent wear on components.

Gear-Shift and Brake Cables

Advice on regular maintenance of gear-shift and brake cables, and replacing defective parts.

Paint Finishes

Guidance on caring for paint finishes to maintain the bike's appearance and check for damage.

Bearings

Information on wear of bearings in headset, hubs, pedals, and bottom brackets.

Sliding Bearings and Bearings for Full-Suspension Frames, Suspension Forks or Other Suspension Elements

Details on wear of suspension components due to high stress and the need for regular checks.

Regular Inspections

Inspection Schedule

Schedule for regular inspections, including initial checks and periodic maintenance.

Link List

Technical Data

Maximum Permitted Gross Weight of Bike

Table detailing maximum gross weights for various bike types and rider weights.

Maximum Permitted Loading of Pannier Rack

Specifications for the maximum permissible load on front and rear pannier racks.

Tightening Torques for Screw Connections

Guidelines for using torque wrenches and general tightening torques for screw connections.

General Tightening Torques for Screw Connections

Table of general tightening torques for various screw sizes and grades.

Tyres and Tyre Pressure

Information on recommended tyre pressures in bar and PSI for different tyre widths.

Lighting Set

Table showing required spare lamps for different lighting sets and their power supply.

Warranty Conditions

Prerequisites for the Validity of Warranty Claims

Conditions that must be met for warranty claims to be valid, including manufacturing and pre-existing faults.

Warranty Exclusions

List of conditions and damages that are excluded from the warranty coverage.

Introduction

Structure of the User Manual

Safety

General

General safety warnings and precautions for operating the Xion Pedelec, including child safety.

Statutory Requirements

Details on national regulations for road safety and specific requirements for Pedelecs.

Battery

Safety instructions for handling, charging, and potential hazards of the lithium-ion battery.

Motor

Safety advice regarding the motor, especially its heat generation and maintenance.

AdjustmentsMaintenanceRepair

Transportation of the Pedelec

The Pedelec and Your Car

Guidelines for transporting the Pedelec on a car rack, including weight considerations.

The Pedelec on Trains

Information on taking the Pedelec on trains, including booking requirements.

The Pedelec on Aeroplanes

Regulations regarding the transport of Pedelecs and batteries on airplanes.

Composition of the Vehicle

First Steps

Checking the Tightening Torques

Instructions to check all screws and components are securely fastened using torque specifications.

Fitting the Pedals

Guide for fitting pedals to the crank arms, noting thread direction and torque.

Adjusting the Saddle Height

Steps for adjusting saddle height using clamp screws or quick-release devices.

Quick Start

Battery

Charging the Battery

Instructions for charging the battery, either on the Pedelec or separately.

Charging Operation

Detailed steps for the charging process, including LED indicators and fault detection.

Installing the Battery

Procedure for correctly installing the battery into the Pedelec holder.

Battery Information System

Explanation of the battery's display panel for checking charge state and capacity.

Battery Management

Information on battery management features like sleep mode and temperature monitoring.

Warranty and Service Life

Details on battery wear parts, warranty, and factors affecting battery service life.

Storage

Recommendations for storing the battery at optimal temperatures and charge levels.

Shipping

Safety warnings and procedures for shipping batteries, noting hazardous material regulations.

Disposal

Information on the correct disposal of batteries according to environmental regulations.

Charger

Control Panel and Display

Control Panel

Overview of the control panel buttons and their basic functions.

Push Assistance

How to activate and use the pushing assistance feature for moving the Pedelec.

Arrow Buttons

Explanation of how to use arrow buttons to adjust power-assist levels.

Display

Description of the display panels and the information they show, including speed and assist modes.

Mounting and Removal of the Display

Steps for mounting and removing the display unit from the handlebar for security.

Menu Availability

Information on when the menu is accessible and how to navigate it.

Battery Charge State Indicator

Explanation of the battery charge indicator using stylized battery segments.

Remaining Range Indicator

How the remaining range is calculated and factors affecting it.

Display Symbols

Explanation of various symbols displayed on the screen, indicating system status.

Programming and Settings

Guide to accessing and adjusting system settings, including tour data and assist modes.

Tour Reset

Instructions for deleting tour data like kilometres, speed, and time.

Assist Mode

How to select and change between assist modes: Boost, Tour, and Eco.

Brake Assist

Procedure for setting up brake assist for downhill riding and selecting a limit speed.

Push Assist

Steps to activate and configure the pushing assistance feature.

Settings

Overview of adjustable settings including date, time, language, units, and information.

The Motor

Operation

Explanation of how the electric motor operates and the factors influencing thrust.

Energy Recovery (Recuperation)

Details on setting and utilizing the energy recovery function for recharging the battery while riding.

Braking Assistance

How braking assistance works for downhill riding and conditions for activation.

Thermal Management

Information on the motor's thermal management system to prevent overheating.

Range

Riding Your Pedelec Efficiently

Troubleshooting

Repair

Removing the Rear Wheel

Steps for removing the rear wheel, including chain and cable disconnection.

Installing the Rear Wheel

Procedure for reinstalling the rear wheel, ensuring correct torque and alignment.

Cleaning

Battery

Instructions for cleaning the battery pack safely, avoiding water ingress and contact shorts.

Motor

Guidance on cleaning the motor, avoiding water and ensuring proper cooling.

Display

How to clean the display housing using a damp cloth.

Control Panel

Instructions for cleaning the control panel with a damp cloth.

Charger

Safety precautions for cleaning the charger, including unplugging from the socket.

Technical Data

Safety Notes

Product Description and Specifications

Intended Use

Defines the intended use of the drive unit exclusively for eBikes on paved paths.

Product Features

Lists and illustrates the components of the drive unit and HMI system.

Assembly

Checking the Battery Pack Before Using for the First Time

Steps to check the battery pack's condition and charge level before initial use.

Charging the Battery Pack

Guidelines for using the correct charger and ensuring proper charging conditions.

Operation

Initial Operation

Requirements for initial operation, including battery pack approval and checking the lock.

Switching On and Off

Methods for switching the battery pack and eBike system on and off.

Notes for Optimum Handling of the Battery Pack

Tips for prolonging battery-pack life through proper maintenance and temperature management.

Recharging the Battery Pack prior to and during Storage

Recommendations for recharging the battery pack before storage and checking its condition.

Storage Conditions

Guidance on storing the battery pack at optimal temperatures and charge levels.

Maintenance and Service

Maintenance and Cleaning

Instructions for cleaning the battery pack carefully with a damp cloth.

After-sales Service and Customer Assistance

Information on contacting authorised bicycle dealers for battery pack support.

Transport

Regulations and requirements for transporting battery packs.

Disposal

Guidelines for the environmentally friendly disposal of battery packs.

Charger

Safety Notes

Critical safety warnings and instructions for using the battery charger.

Product Description and Specifications

Overview of the battery charger and its product features.

Operation

Initial Operation

Initial steps for connecting the charger to the mains and the battery.

Connecting the Charger to the Mains (see Figure E)

Procedure for connecting the charger plug and mains cable to the power supply.

Charging the Removed Battery (see Figure F)

Steps for charging the battery pack when removed from the eBike.

Charging the Battery on the Bike (see Figure G)

Instructions for charging the battery while it is mounted on the eBike.

Charging Procedure

Explanation of the charging process, including temperature range and HMI display.

Troubleshooting - Causes and Corrective Measures

Maintenance and Service

Maintenance and Cleaning

Instructions for maintaining and cleaning the charger.

After-sales Service and Customer Assistance

Contact information for authorized bicycle dealers for charger support.

Disposal

Guidelines for the environmentally friendly disposal of battery chargers.

Safety Notes

Product Description and Specifications

Intended Use

Defines the intended use of the drive unit exclusively for eBikes on paved paths.

Product Features

Lists and illustrates the components of the drive unit and HMI system.

Inserting and Removing the Battery Pack

Operation

Initial Operation

Requirements for initial operation, including battery pack approval and checking the lock.

Switching On and Off

Methods for switching the battery pack and eBike system on and off.

Notes for Optimum Handling of the Battery Pack

Tips for prolonging battery-pack life through proper maintenance and temperature management.

Recharging the Battery Pack prior to and during Storage

Recommendations for recharging the battery pack before storage and checking its condition.

Storage Conditions

Guidance on storing the battery pack at optimal temperatures and charge levels.

Maintenance and Service

Maintenance and Cleaning

Instructions for cleaning the battery pack carefully with a damp cloth.

Transport

Regulations and requirements for transporting battery packs.

Disposal

Guidelines for the environmentally friendly disposal of battery packs.

Charger

Safety Notes

Critical safety warnings and instructions for using the battery charger.

Product Description and Specifications

Overview of the battery charger and its product features.

Operation

Initial Operation

Initial steps for connecting the charger to the mains and the battery.

Connecting the Charger to the Mains (see Figure E)

Procedure for connecting the charger plug and mains cable to the power supply.

Charging the Removed Battery (see Figure F)

Steps for charging the battery pack when removed from the eBike.

Charging the Battery on the Bike (see Figure G)

Instructions for charging the battery while it is mounted on the eBike.

Charging Procedure

Explanation of the charging process, including temperature range and HMI display.

Troubleshooting - Causes and Corrective Measures

Maintenance and Service

Maintenance and Cleaning

Instructions for maintaining and cleaning the charger.

After-sales Service and Customer Assistance

Contact information for authorized bicycle dealers for charger support.

Disposal

Guidelines for the environmentally friendly disposal of battery chargers.

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