Maintenance

X20 is a full system designed to create light e-bikes. The product consists not only of a battery but also of a motor and other accessories such as displays or complex remotes as parts of it. Reliability, simplicity, and the high performance is what define us, following our LIGHT, SPORT and SMART premise.

The components are designed for long term, and they require following some simple and understandable guidelines in their use and handling. If you require assistance when assembling or disassembling the components of the drive system,  please do not hesitate to reach out to us for additional support. Our team of experts will provide you with the necessary guidance to ensure safe and efficient assembly or disassembly of the components.

On the other hand, to ensure proper maintenance of your battery and charger, we  recommend referring to the MAHLE Battery Cares Guidelines provided by our company. These guidelines offer comprehensive instructions and tips on how to maintain the optimal performance of the  battery and charger, helping you prolong their lifespan and avoid potential malfunctions.

If you wish to extend the lifespan of your MAHLE eBike system, please follow the advices we will show you here.

Always make sure your device is updated to the latest version of the system. You can find all the updates here.

Do not leave batteries unused for extended periods of time, either in the bike or in the storage.

• The storage temperature should stay ideally around 20ºC (room temperature) and with a relative humidity of less than 80%. It is important to avoid exceeding a temperature of 25ºC, as doing so may cause irreversible damage to the battery. Therefore, it is essential to monitor and control the storage environment to prevent any potential damage to the battery.
• Store the battery or eBike and the charger always in a dry and cool environment, away from any heating source, flammable materials, flame accelerator or corrosive gas.
• Don’t expose the battery to cold temperatures for extended periods of time.
• If you are going to store the battery or eBike for long term, make sure to keep their State of Charge (SOC) level between 30% and 60% to avoid accelerated deterioration of your battery.
• Never store the battery or eBike (long term) with SoC below 30% or over 90%.
• If the battery is still under warranty period (24 months), it is unnecessary to apply supplementary charging as the battery has an automatic shutdown mode, which is activated after its last usage. However, if the shutdown mode is activated, it is recommended to check the State of Charge of the battery every six months and implement an additional charge when necessary to avoid excessive discharge.

• To minimize the wear of its components, we recommend maintaining the charge of the battery between 20% and 80% of its capacity.
• Once battery is depleted (State of Charge at 0%) make sure you charge it back as soon as possible to an adequate level for storage or use. Remember that it may take some time for the eBike to be able to turn on when the battery is charging after it has reached. 0% Do not worry. Is totally normal.
• If you regularly use high levels of assistance, the discharge of the battery is faster and consequently the useful life of the components will be shortened with respect to using low levels of assistance, where the discharge is made in a lower and more progressive way.
• When starting an activity, we recommend not using the maximum assist right away – your battery needs to reach its ideal operating temperature first.
• Never clean your battery or your eBike with pressure water, this may break the water tightness. You can use a damp cloth for your eBike or rinse it with an adequate soap and a soft brush. Be careful when reaching sensitive areas like the Charging Point or other connectors.

The MAHLE System includes its charger that establishes a direct connection with the MAHLE X20 internal and external batteries, supplying the correct charging current and the ideal balancing of the cells.

• Use only original MAHLE SmartBike Systems chargers to charge originals MAHLE SmartBike Systems batteries. Any misuse of these devices can lead to personal injuries or system damages.
• Connect the charger directly to a power source.
• Never use extension cords.
• Avoid reverse charging (share battery or pass power from another device via cable or wirelessly).
• Do not use for non-rechargeable batteries, as they can overheat and break.
• The charger is not intended to charge automobile batteries.
• Inspect the charger before every use for possible damage of the charger, the wire or and charging plug. Do not cover the charger while charging.
• Never charge a battery which is potentially damaged or does have a defect.
• Make sure the charging socket and plug are not wet or humid before connecting and charging the battery.
• If the eBike or the battery are excessively cold, please wait until the warmed up before charging the system. 
• Do not incinerate, disassemble, or short circuit batteries. Do not charge the batteries near to a heat source or flammable materials. 
• For any cleaning operation disconnect the charger and all general power supply.

During the charging process: 

• Charging a battery from 95% to 100%, is a process that besides causing a long wait, it could reduce the battery’s overall capacity in its useful life considerably.
• Do not leave the charger connected to the bicycle continuously, doing so it could accelerate the degradation of the battery life. Ideally, do not leave the charger connected to the bicycle for more than 5 hours. 
• Make sure that the charging is taking place in a dry environment at room temperature. The charger is designed for indoor use only. Do not expose it to wet conditions, rain, or snow.
• Bear in mind that every time you charge the battery it will degrade. A charging process from 0 to 100% is considered a charging cycle. Charging 5 times from 80 to 100% equals a full charge cycle.

Drive Unit and Drop-Out

The X20 Drive in the rear wheel of your eBike does not have a direct wire connection and uses an automatic connection. When installing or removing the rear wheel, it is important to take care of this connection. Please follow the instructions provided in our Wheel Assembly Guideline or in our User Manual. If you need assistance with the installation of your rear wheel, please contact a  MAHLE directly.

Before installing the rear wheel, make sure that both the motor and the frame side of the automatic connector are clean, and check that all the pins are straight. Failure to properly install the rear wheel could result in damage to either the motor connector or the pins of the Drop-Out.

Regarding the disc brake, the recommended screw lengths: 6 units of M5x8mm. Screws with thread length 10mm may damage the drive unit (10 mm bolts have been tested successfully but we do not recommend their use). Screws with thread length less than 8mm may impact the safety of the braking. Please note that the maximum allowed torque of the through axle is 10 Nm. It is crucial to not exceed this recommended torque to avoid causing axial overloads to the inner motor parts. 

When cleaning your eBike, be sure to remove any dust or mud on the surface of your Drive Unit using a clean cloth. Do not use a power washer to clean any eBike components. The freewheel can be cleaned or replaced by following the specific instructions in our Wheel Assembly Guideline.

Freewheel

The X20 drive unit has been designed to operate exclusively with original freewheels  sets manufactured by MAHLE .The use of non-original parts voids the warranty as well as causing cosmetic  damage to parts or system malfunctions that could lead to dangerous situations that  could result in accidents ending up in personal injury or death. Similarly, incomplete or incorrect installation of the freewheel set that do not follow  exactly the assembly guides can lead to the same results.  If you need assistance with the installation  of the freewheel or you’re unsure about the compatibility of a freewheel, please follow the instructions provided in our Wheel Assembly Guideline.

Assembling requires careful attention to ensure the longevity and performance of the equipment. Prior to assembly, it is essential to clean the shaft using a damp cloth and isopropyl alcohol. Avoid spraying the alcohol directly onto the shaft. Once cleaned, apply assembly grease to the shaft for smooth fitting.

During the fitting process, it is crucial to properly orient the endcap by aligning the inclined faces with the left endcap’s direction. Please ensure that the inclined faces of both endcaps match to avoid potential damages. Take the necessary precautions to prevent any issues that may arise during the assembly process.

The Bottom Bracket (also known as Torque and Cadence Sensor [TCS])  is an essential component of the X20 system, and its proper maintenance is crucial for optimal performance. Due to its delicate nature, mishandling the Bottom Bracket can result in serious damage, ultimately leading to system failure. To ensure that the Bottom Bracket functions optimally, it is imperative that Dealers adhere to the manufacturer’s guidelines and instructions. Please, refer to the MAHLE Assembly Guideline whenever you need help regarding the assembly or disassembly.

 MAHLE disassembly service tools kit is required to uninstall the Bottom Bracket. The use of any other tool  (such as Park Tool Press Fit ) which was not  designed specifically for this operation may cause irreparable  damage to the sensor and render it unusable. The shape and material of the tools are designed to work properly on the frame and to avoid causing aesthetic damage. The TCS Disassembly Service Tool Kit is compatible with all sensor models.   If the correct MAHLE tools are not available or additional support is required, it is recommended to contact  MAHLE directly.

For optimal assembly of the equipment, it is highly recommended to apply standard Anti-Seize grease to all contact surfaces. Additionally, proper positioning of the bottom bracket in the frame is essential. Follow these steps to ensure correct positioning:

• Mark a line between the center of the rear axle and the center of the bottom bracket.
• Place the non-drive side (NDS) sensor cup on the NDS bottom bracket shell.
• Align the white line on the surface of the sensor with the line between the specified centers mentioned above.

The PAS Sensor in the X20 System is an essential component that consists of a high-resolution hall sensor placed in the right dropout of the frame and a magnet ring attached to the freewheel body of the cassette nut. Proper placement of the PAS Sensor is crucial to ensure its correct functioning.

When installing the PAS Sensor, it is important to make sure it is placed inside the dropout and that the cavity is deep enough to protect it from any impacts with the wheel during operation.  Place the PAS Sensor connector into the hole on the right drop-out. The installation of the connector should be smooth, and the connector housing should not be damaged aesthetically. If you face any issue, please contact the designer. Place the M3 grub bolt specified by the OEM. Apply the recommended tightening torque (0,4) to ensure a correct fixation between the PAS sensor and the frame. This will allow you to regulate the distance between the PAS Sensor and the magnet, which should be between 2mm (+/- 0.5mm). Following the given distances is important to ensure that the PAS Sensor signal is correctly read. This will help ensure the accurate functioning of the PAS Sensor, which is essential to providing the proper level of pedal assistance and maintaining optimal performance of the X20 System.

The Head Unit Standard is designed to withstand water splashes and riding in the rain under normal conditions and meet IP67 standards for electrical enclosures. The Head Unit Standard also includes additional protection such as conformal coating and sealed grommets to increase waterproof features. However, it is important to note that leaving the bike parked outside in winter or in extreme weather conditions (rain or snow) can endanger the design and increase the risk of water ingress into the internal structure.

To maintain optimal functioning, it is recommended to keep the buttons and points of contact clean from dust and dirt to avoid damages such as wear or difficulties when pressing the button.

Please adhere to the following guidelines to ensure the safe and optimal use of our product:

• Do not attempt to disassemble or alter this product, as it may result in damage to the system.
• There are small waterproof connectors which are not designed to be repeatedly connected and disconnected, as it may impair their function.
• While our components are fully waterproofed to withstand wet weather conditions, it is advised not to deliberately submerge them in water.
• Do not clean the bicycle using a high-pressure car wash, as water infiltration into any of the components may result in operating problems or rusting.
• Avoid using thinners or similar substances to clean the products, as they may damage the surfaces.
• Be cautious not to let water get into the terminal.
• Please note that normal wear and tear over time is not covered under warranty.
• Before installation, verify that all contents of the box are available

The Charging Point  is typically located at the bottom of the down tube or the seat tube, near the bottom bracket.

The charging point is equipped with a rubber cover.  It is crucial to always keep the charging point closed and covered when you are not charging the bike. This helps to prevent dust and water from getting inside the charging point, which can cause damage to the electrical components or prevent the charger from  fitting properly, which can cause problems when trying to charge the bike.

Finally, it is recommended to avoid exposing the charging point or the bike itself   to extreme humidity conditions.

The eShifters are an optional accessory for the MAHLE SmartBike System, consisting of two small buttons that connect to the Head Unit Standard. The design of the eShifters is minimalist and versatile, allowing them to be installed independently of the handlebar type (drop or flat bar). More detailed information about this product, including installation and usage instructions, can be found in the user manual provided by MAHLE.

Please adhere to the following guidelines to ensure the safe and optimal use of our product:

• Do not attempt to disassemble or alter this product, as it may result in damage to the system.
• There are small waterproof connectors which are not designed to be repeatedly connected and disconnected, as it may impair their function.
• While our components are fully waterproofed to withstand wet weather conditions, it is advised not to deliberately submerge them in water.
• Do not clean the bicycle using a high-pressure car wash, as water infiltration into any of the components may result in operating problems or rusting.
• Avoid using thinners or similar substances to clean the products, as they may damage the surfaces.
• Be cautious not to let water get into the terminal.
• Please note that normal wear and tear over time is not covered under warranty.
• Before installation, verify that all contents of the box are available.

The PulsarONE is a completely wireless display that connects to the system using the ANT+LEV Protocol, which is specifically designed for electric bicycles. For more information about this product, please refer to the user manual.

There are two different optional holders available for the PulsarONE display, which allow four different display positions. It is also possible to use other GARMIN-compatible device holders. To ensure a safe installation, it is important to use a compatible holder with your PulsarONE display.

The display comes with a CR2032 battery that can be easily replaced by opening the tap and inserting a new battery. It is important to follow the correct guidelines when replacing the battery, as indicated on the battery tap. Failure to properly close the tap could result in damage to the contact plate of the PulsarONE display.

Please adhere to the following guidelines to ensure the safe and optimal use of our product:

• Do not attempt to disassemble or alter this product, as it may result in damage to the system.
• While our components are fully waterproofed to withstand wet weather conditions, it is advised not to deliberately submerge them in water.
• Do not clean the bicycle using a high-pressure car wash, as water infiltration into any of the components may result in operating problems or rusting.
• Avoid using thinners or similar substances to clean the products, as they may damage the surfaces.
• Please note that normal wear and tear over time is not covered under warranty.
• Before installation, verify that all contents of the box are available.