User Manual
Welcome Thank you for choosing BionX™. It is our goal to provide you with the highest quality electric propulsion systems available, and offer you the best possible after sales experience. This document serves as a supplement to your bicycle user manual. Please read this manual thoroughly, even if you are an experienced cyclist. Should you be unable to locate an answer in the manual, please contact your dealer for immediate assistance. We have always contended that a bike remain a bike.
User Precautions We want you to have a fun ride, but also a safe one. Carefully read the following information, even if you are an experienced rider. Take the opportunity to familiarize yourself with your BionX electric p ropulsion system before you take your first trip. 1. BionX recommends that you have your system installed professionally by an authorized dealer. 2.
Table of Contents User Precautions 4 Description of the BionX SL Propulsion System 6 Description of the BionX PL Propulsion System 8 Inserting or Removing the Console 10 Inserting or Removing the Battery 11 Handling and Charging the Battery 12 Power supply 14 Chargers 15 Assist Mode / Generate Mode 16 Operating the BionX Propulsion System 17 Operating the G2 throttle 19 Programming the Basic Settings 20 Removing and Installing the Rear Wheel 21 Maintenance and Care 22 Cleaning 2
Description of the BionX SL Propulsion System 1 1 4 2b 2a 3 4 3 1 G2 Console • Removable G2 console • Illuminated LCD display with battery state of charge • 4 assistance levels • 4 generate levels • Backlight and bicycle light controls • Offers cycle computer functions (speed, odometer, clock, average speed, trip distance) Remote throttle (where applicable) • Assistance/Generate Toggle • Variable control throttle lever 2a 48V Down Tube Battery • Lithium Manganese (LiMn) • Removable, lockable • Ful
3 SL Motor • DC rear, high torque (HT) hub motor • Nom. 250W (EU), 350W (NA) • Nom. 9Nm / max. 40Nm (6.6/30lb-ft) • 1.2 Kg (2.
Description of the BionX PL Propulsion System 1 1 4 4 2b 2a 3 3 1 G2 Console (systems 2011 to present) • Removable G2 console • Illuminated LCD display with battery state of charge • 4 assistance levels • 4 generate levels • Backlight and bicycle light controls • Offers cycle computer functions (speed, odometer, clock, average speed, trip distance) 3 2 1 4 Remote throttle (where applicable) • Assistance/Generate Toggle • Variable control throttle lever 1 G1 Console (systems 2010 and earlier) • G
2b 37V Rear Rack Battery • Lithium Manganese (LiMn) • Removable, lockable • Fully charged in: 4-5h • RR L - 37V / 9.6Ah / 355 Wh • RR M - 37V / 6.4Ah / 236 Wh 50, 250HT (EU) / 350HT (NA), 3 2 or 500* watt Motor • DC rear hub motor • 250W : nom. 7Nm / max. 25Nm (5/18.5 lb-ft) • 250HT (EU) / 350HT (NA): nom. 9Nm / max. 40Nm (6.6/30 lb-ft) • 500W : nom. 9Nm / max. 25Nm (6.
Inserting or Removing the Console “click” Inserting the console • Slide the console into the console mount on the handlebar • Make sure that the console engages securely.
Inserting or Removing the Battery Inserting the down tube battery 1 Place the battery into the docking station 2 Slide the battery down the rail gently towards the connector 3 The release arm will close automatically as the battery slides towards the connector 4 W ith the release arm almost closed, hold it in place and simultaneously press in the lock cylinder – you will hear a “click” when the lock cylinder is properly closed WARNING Do not force the battery arm closed, or force the battery onto the ba
1” Inserting the rear rack battery: 1 Open the lock cylinder: please ensure that the key is removed from the lock cylinder 2 Place the battery onto the battery harness 3 Gently push the battery in a forward direction, towards the battery connector Make sure the battery is inserted all the way, flush with the battery connector 4 Push in the lock cylinder until a ‘click’ is heard (2 ) m 4m 5. WARNING 001 001 Do not force the battery onto the battery dock.
Make sure that the battery is no longer connected to the power supply or charger once the charging operation is complete. The Lithium Manganese battery cells have a low self-discharge rate, therefore a continuous connection of the battery to the power supply or charger is not necessary. We recommend that you fully charge the battery when it will not be used for a longer period of time, for example, before storing it for the winter, and then recharge the battery at minimum every three months.
Power supply SL system charging procedure (power supply) • Connect power supply and battery by inserting the charge connector into the touch port – the system can be turned on or off • Connect the plug of the power supply with the power outlet • The battery touch port (LED ring around the charging connector) lights up red upon inserting and then turns to amber during the charging process • When fully charged, the colour of the LED ring changes to green.
Chargers PL-250HT (EU) / PL-350HT (NA) systems charging procedure, 2012 - present (single light charger) • Connect the charger and battery by inserting the charge connector into the charge port.
Assist Mode / Generate Mode The BionX propulsion system operates in four assist levels in the assistance mode, and in four charging levels in the generate mode. In the assistance mode, your pedaling is assisted proportionally by an electric motor that drives the rear wheel. A torque sensor is located on the axle of the electric motor and measures the effort provided by the rider; this produces natural feeling assistance from the motor.
Operating the BionX Propulsion System G2 Console 7 11 1 2 6 9 4 10 1. Power 2. Key 3. Key 4. Cycle 5. State of charge indicator 3 5 8 6. (bicycle) mode 7. Speedometer 8. Trip distance/average speed/ chronometer/odometer/clock 9. Assist level (A) 10. Generate level (G) 11. Wrench symbol Turn the system on Briefly push either top button on the console. The battery will beep 4 times and you will see a countdown, this is the system perfoming a self check.
Turn on backlight and bicycle light (if applicable) Push and hold key for 4 seconds - display backlight and bicycle light (if available, battery integrated) are turned on. 4s Turn off backlight Push and hold key again for 4 seconds.
Operating the G2 throttle Throttle engagement: Default min. 3 kph to engage throttle Note: throttle control is variable, and the force gauge on the console reacts proportionally Assistance levels 1-4: From press for more assist or for less assist Generation 1-4: From press for more resistance or for less resistance NOTE The G2 throttle is only compatible with the G2 console, and may not be available in all countries. Check with your local BionX dealer for local legislation and/or availability.
Programming the Basic Settings In general, all basics settings for your BionX electric propulsion system are pre-set. Basic display functions can be set by entering the programming mode. Contact your dealer to customize the advanced functions of your system. Turn on the programming mode Simultaneously push and until the display shows “0000”. The first zero blinks. Change the value of the selection with or and confirm with . Select the other digits in the same manner until the desired program is displayed.
Removing and Installing the Rear Wheel We recommend the removal and installation of the rear wheel to be done by a qualified dealer. Should you have to do this yourself, please follow the instructions below: WARNING Always turn off the propulsion system prior to plugging in or unplugging the motor cables. CAUTION It is essential that the axle nuts are tightened with a torque of 40Nm/30lb-ft; this assures that the propulsion system functions properly.
Installing the rear wheel 1 Guide the rear wheel axle into the dropouts and make sure that the brake disc (on models with disc brakes) is inserted between the brake pads. Also make sure that the flat area at the left of the rear axle (torque reaction collar) is aligned so that it fits into the left dropout (no illustration). Make sure the axle is inserted all the way in the dropouts 2 T ighten the axle nuts on the rear wheel with 40Nm/30lb-ft (= VERY TIGHT!).
Cleaning CAUTION Never use a high pressure washer or a garden hose to clean the propulsion system. The force of a water jet could damage the electrical components of the propulsion system. We recommend a soft sponge or a soft brush to clean the bicycle. Use a moist rag to clean the battery’s docking station. Always use very little water, and keep water away from the electrical contacts. Check the plug-in connections for moisture after cleaning and let these dry, if necessary, before reusing the bicycle.
Troubleshooting The system does not turn on Check the battery and make sure that it is charged. The battery must be correctly inserted in the docking station and the lock must be completely closed. Also check that all connectors of your wiring harness are properly engaged, and your console is inserted properly. If the problem persists, contact your authorized dealer. The system can be turned on but there is no assist Check that the cables running from the battery to the motor are properly connected.
Warranty Information and Guarantee 1. The BionX warranty covers a two-year period for BionX propulsion system(s) within the framework of the following conditions. 2. This warranty exclusively covers systems provided by BionX excluding all the other bicycle components provided by other bicycle manufacturers. 3.
11. No warranty claims are accepted - without limitation to other reasons - in the case of damages due to the following: a) External influences, particularly falling rocks, collision, accident and other external events with an immediate external effect due to mechanical powers. b) Purpose and/or malevolent acts, theft and robbery as well as natural hazard events and/or acts of mischief. c) Test, maintenance, repair and replacement work due to normal use.
BionX, BionX Design and powered by BionX are trademarks of BionX International Corporation. ©2011 BionX International Corporation. All Rights Reserved.
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