OPERATING INSTRUCTIONS
Contents
1. OPERATING INSTRUCTIONS Panasonic DRIVE SYSTEMS English Congratulations Congratulations on your decision to buy a product manufactured by KTM We are sure that your new Pedelec will more than fulfil your expectations in function design and quality both Now and in the future All KTM Pedelecs are manufactured under the latest production methods and with high quality materials and are equipped with the best components according to their function We would like you to read this guide carefully so that you can experience untroubled driving pleasure with your new Pedelec by KTM Please make sure that your new Pedelec is handed over to you from KTM completely assembled adjusted and with all instructions This manual is a supplement to the KTM Bike Pass Should you have any questions after reading the manual please contact your KTM dealer Safety and Performance Please follow all national road laws and regulations Make sure that frame size and controls are matched to your body height Check before driving whether the brakes lights and other safety related components are functional and free of defects Never drive without the lights on at night Never carry a passenger on your bike Exception carrying a small child in a special child seat Please note that the driving characteristics may change dramatically under load Always wear a helmet Page 1 Description of the Panasonic drive s2. To allow the drive system to react properly to your pedal pressure this automatically performs a calibration during the first two seconds after power ON During this process the torque applied on the pedal bearing is determined and it is reset to the zero starting value If you now place pressure on the pedal during power up the drive system measures the wrong value and it can then subsequently gil react improperly an error is indicated This will be indicated in the Pedelec with LED control panel by alternating flashing of all LEDs of the support levels and of all LEDs of the battery charging level in the Pedelec with LCD control panel by the El error signal PA In this case you should turn the drive system OFF once more and ON again with the POWER button without exerting pressure on the pedals in this way the error should be corrected Adjusting the levels of support LED control panel By pressing the Assist button UP or DOWN the support level can be adjusted There are three different levels of strength of support available ECO STANDARD HIGH When you turn the drive system ON the support level is pre set to STANDARD LCD control panel By pressing the Assist button UP or DOWN the support level can be adjusted There are three different levels of strength of support available ECO STANDARD HIGH When NO ASSIST is indicated the system provides no support When you turn the drive system ON the
3. step braking function brushless DC motor voltage level 36 V high efficiency nominal power 250 W nominal torque 21 Nm torque sensor on the pedal bearing axis Centre Motor 25V brushless DC motor voltage level 25 V high efficiency nominal power 250 W nominal torque 21 Nm torque sensor on the pedal bearing axis System System System 36V 36V RT 25V I dentificati Illustrati System System System ini RR 36V 36V RT 25V aE r Speed sensor X X LED control panel LED display with backlight 3 levels of assistance 50 120 200 charging level display current support E High E Mid MODE E Low vE E xx xx xx LCD control panel LCD display with backlight 3 levels of assistance 50 120 200 charging level display current support current speed odometer trip average speed Mx gt xx 10 Padlock Ring Cia Mx Cia Depending on configuration the various batteries and control panels are selected differently by KTM The X shows the compatibility of the components with the respective system KK Page 4 Special KTM Pedelec models are supplied without padlock ring System System System I dentification Illustration 36V 36V RT 25V 36V fast charger l j Special charger for charging i Li Ion batteries suitable for i 7 100 230 V 50 60 Hz power F supply line output volta
4. In principle we recommend that you remove the battery and protect the plug contacts from contamination when transporting the Pedelec on a car rear or roof carrier Appropriate protective caps are available from your dealer Repairs and Spare Parts Refer all repairs of the drive system to the trained specialists of your dealer All original spare parts for your Pedelec may be obtained from your KTM dealer Should you need spare keys for the battery lock please also contact your local dealer therefore make a note of the key number for this eventuality Troubleshooting SYMPTOM SOLUTION Is the battery charged Has the battery not been used for a long time gt Please charge the battery A Was the battery used for the first time gt Please charge the battery The range could be reduced by the road surface conditions gear selection or by The LEDs for the battery erratic driving behaviour charging level on the control panel blink after a short ride The decrease in range is normal in winter due to the low temperatures x Is the air pressure in the tyre too low gt Please pump air into the tyre Is the brake properly adj usted gt The brake should be properly adjusted by your dealer Page 17 7 e A a un 2 V LLI a gt o o A 4 un cc a LLI L SYMPTOM The LEDs for the support mode or for the battery charging level on the
5. SETTING TYRE SIZE SETTING TOTAL LANGUAGE LCD CONTRAST KM MILES ADJ USTMENT KILOMETRES 6 SET WITH W AND WITH W AND A wth Wand A 4 SET WITH YW AND WITH Y AND A VODE p MODI SETTI NG TOTAL EE Se N TYRE SIZE 3 SET MOD witH V AnD amp 4 SETTI NG TOTAL KILOMETRES 4 SET WITH YW AND SETTING TYRE SIZE 2 SET Guar Vai SETTING TOTAL KILOMETRES 3 SET ODE WITH W AND SETTING TYRE SIZE ETTING TOTAL 1 SET 9 n KILOMETRES 2 SET WITH W AnD WITH W AND amp SETTING TOTAL KILOMETRES SI 1 SET WITH V AND A DIRETE ELI i 1 SET 4 DIGIT 1 SET 6 SET Page 14 JGOW Adjustment of the speed sensor only with 36V drive systems The good function of your Pedelec is only guaranteed with a correctly adjusted speed sensor Should the speed sensor be set incorrectly the drive system makes significant errors visible through the control panel In the Pedelec with LED control panel the current support level flashes thus indicating a malfunction in the Pedelec with LCD control panel the display indicates the E2 error The speed sensor is set correctly when the spoke magnet is located just above the notch of the speed sensor see Illustration The spoke magnet should always be aligned so that it is situated right in the intersection area of the spokes so that it cannot twist see Illustration The adjustment of the speed sensor is done through two fixing screws on the lower side of the
6. control panel do not light up The charging status LEDs blink fast or do not light up at all The LEDs for the charging level and support mode blink alternately The charging status LEDs blink twice and the support mode LED blinks once alternating with each other SOLUTI ON Is the battery fully engaged gt Please re engage the battery into the holder If you press the battery charging level button and the 2nd and 4th LEDs are lit the safety device of the battery is active gt Please charge the battery If you press the battery charging level button and none of the LEDs is lit the safety device of the battery is active gt Please charge the battery If the problem cannot be resolved contact your dealer Is the battery charged gt Please charge the battery Were you pedalling while you turned the system ON gt See calibration of the drive system while turning ON P 13 The system could have an error gt Contact your dealer z o A A un e Z 14 LUI a gt e oe A gt un cc ml LLI I THE BATTERY DOES NOT CHARGE SYMPTOM The charging level LEDs blink three times and the support mode LED blinks once alternating with each other The system is turning automatically ON and OFF Support turned OFF The battery charging level LED does not light up Page 19 SOLUTION Durin
7. left chain stay see illustration By loosening the locking screws it is possible to adjust the speed sensor along the chain stay forwards or backwards After the adjustment is completed the locking screws should be re tightened Proper adjustment of the speed sensor Proper placement of the spoke magnet and mounting screws at the bottom of the left chain stay TINO wr o a n Page 15 Maintenance and Care Regularly check the tightness and seating of the nuts holding the rear wheel hub and the bolt for the engine support for models with the coaster brake The nuts holding the rear wheel hub must be tightened to 20 Nm VERY FIRMLY Compliance with this tightening torque is essentially required for the proper function of the drive It is strongly recommended that the mounting nuts and bolt for the engine support ATTENTION are checked and re tightened immediately after the first 10 km of receipt of the bike since the screw connections must be allowed to settle in the new bike Pay attention to the chain tension when using a Model that is equipped with a drive system with a coaster brake function too little tension of the chain can negatively affect the braking performance of the coaster brake We recommend checking by the dealer of the spoke tension of the wheels and all bolted connections including the motor screw connections after the first 200 km It should also be noted that shorter maintenance inte
8. support level is pre set to STANDARD Operation of the speedometer functions For LCD control panel only The speedometer functions TOTAL KM odometer TRI P KM Trip O KM H Average speed MAX KM H Maximum speed will be displayed under the speed readout on the LCD display To switch from one function to another press the MODE button briefly to reset the trip odometer travel time and average speed to zero press the MODE key for longer than three seconds Page 13 Programming of basic settings For LCD control panel only Basically all the basic settings for your Pedelec are optimally selected by KTM However should you change a tyre for example for service purposes you can to ensure the exact function of your speedometer set the tyre diameter anew Furthermore you can change the setting of the control console language the contrast of the LCD display the speedometer indication unit and the odometer indication unit The following diagram illustrates the setting of the individual setting parameters ___ NORMAL OPERATI NG MODE Normal operating mode P Setting mode To exit the setting mode from all levels press the LIGHT button To enter the setting mode press MODE amp for longer than 3 seconds pr Y SETTING THE LA SETTING THE T SETTING KM TYRE SIZE Y SETTING TOTAL LANGUAGE pata LCD CONTRAST Palla MILE i ADJ USTMENT F KILOMETRES 4 A A A A d ZN AN AN A A SETTING THE SETTING THE
9. at all times according to actual needs since the effectiveness of the drive system increases with the correct choice of the support level Operation of the drive system DOI O 6 1 5 8 6 0 Example of display LED control panel LCD control panel during operation POWER button to turn the system ON and OFF Indication of charging status of the batteries MODE button for setting the support level Indication of the level of support LIGHT button to turn OFF the backlight Assist UP button to increase the level of support Assist DOWN button to decrease the level of Support Indicator light ON or OFF Indication of the current consumed energy OONAUBWNE 10 Indicationof the current speed 11 Speedometer function indication value current value for the displayed speedometer function 12 Speedometer function indication TOTAL KM odometer TRIP KM Trip km O KM H Average speed MAX KM H Maximum speed Turning the drive system ON and OFF LED control panel LCD control panel Press the POWER button to turn the drive system ON At the beginning all LEDs light red after two seconds the current battery charging level and the support mode set will be indicated by the red LEDs To turn OFF press the POWER button again Page 12 Calibration of the drive system when turning ON Never turn the drive system ON and OFF with pressure exerted on the pedals This may result in functional failures ATTENTION
10. charging cycles to such an extent that the battery indicator displays only one LED light emitting diode If the battery is no longer being used it must be fully charged every three months Too high and too low temperatures are very bad for the battery especially during charging It is necessary to avoid charging batteries in direct sunlight or on heaters This will significantly reduce the battery life We therefore recommend charging the battery pack in temperatures of approximately 20 C After a ride in a cold environment the battery should first be warmed to room temperature 20 C before charging Page 8 Inserting the batteries into the charger Plug the charger into the wall socket 220 220 240V 240 V and insert the battery into the charger Plug Battery Charger Removing the batteries from the charger Remove the battery from the charger after you have verified that all LEDs are not lit wA Pull down and remove fully charged Now you can unplug the while the charger is charger from the wall outlet AC 220 240 V firmly held The power consumption of the charger in standby mode is 1 5 W The red light emitting diodes LEDs will indicate the battery charging level on the battery 5 LEDs and on the control panel 3 Checking the battery charging LEDs The number of the LEDs lit depends level on the current battery charging level With the drive system ON the battery level Panasonic will b
11. e indicated on the control panel The battery charging level may be indicated on the battery by pressing the PUSH button While charging the battery seated in the charger see Charging the batteries the ii current charging level will be indicated II through the five red LEDs on the battery If VW the battery is fully charged all five LEDs go Battery charging level indicator OFF on the battery Page 9 Status of the battery charging level indicator on the battery Status of the Status of the battery charging battery charging level indicator on level indicator on battery the LCD control the LED control O 20 40 60 80 100 panel panel Remaining capacity of the Button for battery charging level Battery charging level indicator 4 LEDS light red 3 LEDS light red 2 LEDS light red 1 LED lights red 1 LED blinks red All 3 LEDs light red approximately 100 70 approximately 100 80 Battery charging level indicator 7 approximately 80 60 2 LEDs light red approximately 70 40 approximately 60 40 approximately 40 20 1 LED lights red approximately 40 10 er approximately 20 10 Slow blinking approximately 10 0 L approximately 10 0 Fast blinking off Page 10 In the following cases the LEDs on the battery charge indicator light up but the system does not support it The ba
12. enuine batteries for retrofit and replacement purposes WARNING The use of third party or unsuitable drivetrain components and or batteries can cause overheating ignition or even explosion of the batteries It also invalidates any guarantee and warranty claim Installing and removing the batteries Installing the Panasonic batteries Insert the battery from above at an angle into the battery holder The battery level indicator must be on the side of the battery facing you Tilt the battery upwards until it engages in the lock Make sure by pulling the battery that it is securely locked otherwise the battery may be released from the WARNING holder Page 6 Removing the Panasonic batteries Hold the battery and simultaneously turn the key 90 degrees counter clockwise Slowly pull the battery in your direction The key remains in the open position In this position it cannot be pulled out Hold the battery pack in both hands so that you can remove it safely Then turn the key 90 degrees clockwise and pull it out After removing the batteries remove the key and keep it safely Hold the battery while you turn the key otherwise the battery may release from the holder WARNING Handling and charging the batteries Never short circuit the battery by connecting the terminals This could lead to overheating ignition or even explosion of the battery Never try to open the battery This could lead to a s
13. eriod Repairs and direct replacement under warranty can be performed with functionally equivalent replacement units The guarantee does not apply if defects other than defects of material or workmanship are found The following items are NOT covered by warranty 1 2 3 Testing maintenance repair and replacement service on the basis of normal usage If the battery does not reach the full capacity based on normal usage By improper use The product was exposed to liquids chemicals of any kind and or to extreme temperatures moisture or humidity Damage of the battery by ignoring the special instructions in the chapter Handling and storage of the battery or the chapter Use only Panasonic original components Page 21 4 The model number serial number or product number on the product has been changed erased made illegible or removed The seal on the battery case has been broken or obviously tampered with 5 Useof batteries in systems which are not permitted to be used with this product the batteries may be used only in the product which they were shipped with 6 Accidents acts of God or causes beyond the control of KTM caused by water fire public disturbances or inadequate use humidity 7 Damage of the batteries by overcharging or failure to comply with the special instructions for handling the batteries see User nformation 8 The batteries were recharged with chargers that do not belong to the drive
14. g overloading the system operates in safe mode due to current overheating In safe mode the support is limited if the normal function condition is not restored ask your dealer Is the cabling loose or are the connectors contaminated gt Contact your dealer Does this happen after you have been stationary for five minutes gt System in idle state please turn the system ON again Is the battery properly engaged Are the battery contacts contaminated gt Please clean the battery contacts Is the battery fully charged gt Check the remaining battery capaci by pressing the charging level button A fully charged battery cannot be re charged Charge the battery after it is used Was the battery level button pressed while pedalling and the charging status LED blinked gt Contact your dealer SYMPTOM Battery and or charger become hot Remember that the battery and or charger may ignite None of the five battery charging level LEDs lights up after charging You feel vibrations when you place a foot on the pedal when stationary Page 20 SOLUTION The charger is warm during the charging process gt Normal behaviour of the charger Is the charger so hot that it is impossible to touch gt Immediately stop usage and contact the dealer Was the battery removed while charging gt Please re charge the battery Is the connector of the charger contaminated gt P
15. ge LAS output voltage 42 0 V output i fl current 4 1 A output power i 35 195 W 25V fast charger Special charger for charging p Li Ion batteries suitable for i A 100 230 V 50 60 Hz power Id E supply line output voltage P output voltage 29 3 V output a iz current 4 0 A output power i 140 W e Compatibility of Panasonic drive systems 36V and 25V WARNING To charge your batteries use exclusively only the provided power supply supplied with the bike Using third party or unsuitable chargers can cause overheating ignition or even explosion of the battery The drive components of the 36V drive system and of the 25V drive system are not compatible and they are secured against interchange Never try to use incompatible drive components this could result in danger for you and for other persons Furthermore the entire warranty and guarantee claims expire To avoid mixing up the different batteries there are different battery holders installed in the 36V system and 25V system A tab on the battery holder of the 36V drive system prevents insertion of an incorrect battery The tab is also situated on the 36 V charger 36V system battery holder 25V system battery holder Page 5 Use only genuine Panasonic components Only genuine Panasonic drive components and Panasonic original batteries are installed in KTM Pedelecs Therefore use exclusively only Panasonic original drivetrain components and g
16. hort circuit and in consequence to overheating ignition or even explosion of the batteries The battery may not be serviced by the user If the battery cover is opened all warranty and guarantee claims expire WARNING Do not use any batteries which have the case or plug obviously damaged Make sure that the fully charged battery after completed charging is no longer connected to the charging power supply The Lithium Manganese battery cells used have minimal self discharge therefore no permanent connection with the battery charger is necessary Basically it is quite sufficient to charge the battery every three months Before long periods of inactivity e g before a winter break we recommend that the battery be fully charged and then subsequently every three months It is best to store the unused batteries in a cool place at temperatures between 5 C and 25 C Never charge the batteries in places where the temperature may be above 45 C or below minus 20 C The battery should never be exposed to extreme temperature fluctuations or humidity and it is essential to protect it from moisture during storage to prevent corrosion on the plug contacts Never let the battery drop and protect it from mechanical damage Damage could lead to a short circuit and in consequence to overheating ignition or even explosion of the batteries Page 7 Used batteries do not belong in the household refuse It is important to note that used batte
17. lease clean the connector Is the battery already quite old and is it used very often gt The battery life may be at an end These are the characteristics of the motor Information on warranty and guarantee The warranty and guarantee provisions specified here are complementary to the KTM Bike Pass in terms of the features of the Pedelec drive components listed below For motor and control unit the warranty legally valid at the time of shipment applies Provisions for the batteries of the KTM Pedelec 1 The guarantee applies only to material or workmanship defects and only upon presentation of the proof of purchase consisting of an original sales receipt or cash receipt with the specified date of purchase dealer s name and model number of the bike in which the battery is used for two years from date of purchase KTM reserves the right to refuse the warranty service if the documents submitted with the battery are incomplete In the case of a warranty KTM undertakes to repair the claimed batteries or at the discretion of KTM to replace with the equivalent replacement or spare part Warranty repairs will be performed in the premises of KTM Costs for repairs which were performed at a location not previously approved by KTM will not be refunded In this case the warranty will be void Repair services or replacement during the warranty period do not entitle the owner to an extension or to a restart of the warranty p
18. ries must be disposed of properly Charging the batteries To charge your batteries use exclusively only the provided charger supplied with the bike The use of third party or unsuitable chargers can cause overheating ignition or even explosion of the battery The charger shall be used exclusively with rechargeable batteries The use of non rechargeable batteries can cause overheating ignition or even explosion of the battery It is necessary to ensure that the battery and the charger do not get wet or damp during charging or when the charger is connected to the network and or turned ON so as to avoid electrical shocks and short circuits Do not use any chargers which have the cable case or plug obviously WARNING damaged Allow only children over 8 years of age to use the charger and give the respective child corresponding safety and detailed instructions for charging the batteries Make it explicitly clear to the respective child that the charger is no toy and that the charger should only be used for rechargeable batteries The Li lon battery employed has no memory effect and it also does not to have be fully discharged and charged We recommend charging the battery after each ride if the battery level indicator is already showing less than 50 We further recommend charging the battery completely before long periods of inactivity for example before a winter break It is best for your battery to be emptied during the first three
19. rvals should be complied with for Pedelecs than for regular bicycles because of higher loads Your dealer will gladly provide you with the relevant advice To maintain the lasting and good functionality of the drive system all plug contacts of the drive system should be reviewed every two to three months and if necessary cleaned with a soft dry brush It must be ensured that no dirt or moisture gets into the battery holder The electric motor is a brushless DC motor which does not have to be serviced Cleaning Never use a pressure washer to clean the drive system A strong jet of water could damage the electrical components of the drive system ATTENTION We recommend cleaning the bike with a soft soonge or a soft brush To clean the battery holding rail use a damp cloth Always work with a little water and keep water away from the electrical contacts After cleaning check the connectors for moisture and let them dry if necessary before re starting the bike Page 16 Transport of the Pedelec on a car roof rack or rear rack Please pay attention that the employed car rear or roof carrier is also suitable for the increased weight and that it is specifically intended for the special frame shape of the Pedelec An unsuitable carrier can be damaged or broken during the transportation of the Pedelec and it therefore represents a great WARNING danger In addition the Pedelec itself may be damaged by an unsuitable car rear or roof carrier
20. system 9 Unauthorised modifications made to the product by which the product does not comply with local or national technical standards in the countries for which the product was originally released by KTM 10 Less power less than 70 of the battery if it has been completely charged and discharged more than 500 times within the warranty period of two years Warranty disclaimer KTM shall not be liable for property damage downtime pawn or rental equipment travel expenses lost profits or similar The liability of KTM is limited to the purchase price of the product The rights of the purchaser according to the applicable national legislation that is which are derived from the purchase contract of the buyer towards the seller as well as other rights will not be affected by this warranty This warranty is the sole and exclusive remedy of the purchaser and neither KTM nor its subsidiaries are liable for incidental or consequential damages or injury to any statutory or contractual warranty obligations for this product With regard to the rest of the bike components the provisions specified in the KTM Bike Pass apply Page 22 OPERATI NG INSTRUCTIONS PANASONI C DRIVE SYSTEMS Specifications subject to change No liability for mistakes and misprints Rev Fall 2011 ART No 00012000011 KTM FAHRRAD GMBH Harlochner Strafgse 13 5230 Mattighofen Austria
21. ttery is new It has not been used for a long time It is used on a cold day ATTENTION When approaching a steep hill In this case you have to charge the battery again Drive mode The drive system works in three levels of support in the Drive mode They will be supported by the drive system automatically without any operation of an accelerator A torque sensor is located in the axis of the pedal bearing and it measures the force applied by the driver According to the measured force the power of the supporting electric motor will be regulated accordingly Support step gear A Support level Steep hills 0 3 200 strong headwind Expected maximum range The maximum range of the battery depends greatly on various factors such as the selected level of support the road surface weight of the rider tyre pressure and ambient temperature The following are the maximum performance characteristics possible O 20 40 60 80 100 120 140 160 180 km km km km km km km km km km 50 Battery 36 V 14 Ah Battery 36 V 12 Ah 120 200 Page 11 Concerning the driving feeling there is no difference whether the drive system is operated with the support switched OFF or on level 0 When the drive system with the LCD control panel is switched ON all the speedometer functions are available The drive system works most effectively at a cadence of 60 revolutions per minute We recommend selecting the drive level
22. ystem Your KTM Pedelec is an EPAC Electrically Power Assisted Cycle according to EN15194 and differs in the following points from a bicycle without drive assistance KTM basically installs three different Panasonic drive systems Model year 2012 36V Centre Motor Drive System in combination with an idling free wheel hub 36V Centre Motor RT Drive System with the coaster brake function in combination with a coaster brake hub 25V Centre Motor Drive System in combination with an idling free wheel hub Drive system components and system applicability ela System System System I dentification Illustration 36v 36v RT 25V Original Panasonic Battery 36 V 14 Ah D System 1 Sanyo Li lon Technology 36 V 14 Ah 504 Wh 4 4 kg full charging in about 5 hours at least 500 charging cycles possible X X Page 2 I dentification I Illustration Original Panasonic Battery 36 V 12 Ah ID System Sanyo Li lon Technology 36 V 12 Ah 432 Wh 3 6 kg full charging in about 4 hours at least 500 charging cycles possible Original Panasonic Battery 25 V 12 Ah ID System Sanyo Li lon Technology 25 V 12 Ah 302 Wh 2 8 kg full charging in about 4 hours at least 500 charging cycles possible Centre Motor 36V brushless DC motor voltage level 36 V high efficiency nominal power 250 W nominal torque 21 Nm torque sensor on the pedal bearing axis Centre Motor 36V with back
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