Bosch Tuning Dongle Fitting Guide -

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1 Bosch Tuning Dongle Fitting Guide - Please read these instructions carefully before fitting and keep them for later use. Please be aware that the use of the tuning dongle is strictly for off road use only. The dongle allows your ebike to reach assisted speeds of approx. 35mph, this is of course past the UK assistance limit of 15mph. The dongles come in 3 sizes 20, 26 & 28/29 Please make sure you have the correct dongle. You are using the tuning dongle at your own risk. Therefore no warranty is implied to the unit itself or the ebike, by fitting the tuning dongle this could invalidate your motors warranty from the manufacturer. Description Features: The tuning dongle is a sealed unit, maintenance free and requires no battery. Your Bosch interface will measure your bikes speed, please note with the dongle fitted your speed onwards of 15mph will be altered by the dongle. Therefore your interface will read the wrong speed. You can roughly work out what speed you are going by doubling the speed shown on the interface. The plug is small and compact and can be un-plugged to revert the bike back to normal conditions. Before you install: The Sx2 cable kit is compressed parallel to the speed sensor with gel-cutting clamps. For this installation, the protective cover will need to be removed from the motor terminal box. Contents: 1x Cable Kit with 3.5 mm jack 2x Gel Insulation 3M Connectors 1x Sx2 Tuning Dongle 1x Sx2 tuning dongle Cable Kit. 2 x Heat shrink wrap. 2 x Cable Ties Page 1 of 6

2 In the instructions below the picture on the left is for Bosch upside down motor (sits below frame, KTM etc.) The picture on the right is for Bosch top mounted motor (sits inside frame, Haibike etc.) Installation: Remove the crank bolt with a 8mm Allen key Then remove the right crank with a ISIS Crank extractor. Do this by screwing the outer thread of the tool all the way into the crank (screw in as far as possible), then wind in the inner part of the tool to pull the crank off. Use the spider tool to remove the lock ring. (NOTE: LEFT HAND THREAD!) Page 2 of 6

3 Now you can pull the chain ring from the shaft. It may be that the Spider has slightly jammed on the shaft. So be careful from behind with a piece of wood or a screwdriver pry the Spider from the shaft. Now un screw the 3 Torx screws with a Torx T20 wrench and take off the stone guard from the side. Remove the connector from the speed sensor. (The dummy plugs with the plastic inserts are for the light cable, headlight and taillight) Page 3 of 6

4 Pull the speed sensor connector out and strip back the insulation by about 5 cm. Now you can begin to connect the dongle wiring to the speed sensor using the supplied clips. Connect the Red/Black wire of the kit to the black wire on the speed sensor. Make sure the wires are all seated exactly in place, the 3M connectors can only be used once. If the wires are not seated correctly and therefore the3m connector does not splice them; the dongle will not work. Compress the clip with pliers to seat the connector. Note: Some silicone gel may squeeze out of the side of the connector. This is normal. It allows the connection to be water tight and prevents corrosion on the connection. To keep it neat place the connectors parallel to each other on the cable (this will help if you apply heat shrink wrap). Now connect the red wire of the kit to the red wire on the speed sensor. Page 4 of 6

5 Now you can slide the heat shrink tubing over the connector and heat seal using a heat gun / hairdryer. The dongle cable is now connected and you can plug the speed sensor back into the motor unit. Testing : Leave the Bosch cover off, slide the crank and spider back on and raise the back wheel off the ground. This way you can test before putting it all back on neatly, saving you time. With the dongle not in place, spin the bike up, in the hardest gear and you cranking hard you should read around 30mph. (Be careful to tuck wires out the way and to not snag anything with the chain) Now with the power turned off, press the dongle into the holder. Then turn the power on. Now pedal the cycle again in the same gear, it should now read totally different with the display reading up to about 18mph with you pedalling the same rate. You now know it is working before assembling the bike back together. Mounting: Slide the dongle through between the frame and motor. You can secure the remainder of the dongle wiring to the frame with cable ties. Mount it somewhere easy to reach if you are to be removing the dongle a lot, alternatively if you plan on leaving it fitted you can neatly tuck it out the way. Then proceed to fit the components back on in reverse order. Page 5 of 6

6 Tightening Torques - Stone guard 1 to 1.5 Nm Lock ring (left-handed) 40Nm (Alu) 30Nm (plastic) Crank Bolt NM Now plug in the dongle to the dongle holder. IMPORTANT! Make sure you do not run gearing sprockets that equal 1:1, if you do you will display an error code on the Bosch display. Error code 102. For example if your gearing is 44tooth front sprocket to 22 rear sprocket; this is 1:1. If you have this you can simply change the rear cassette to another one that doesn t feature the sprocket giving you the error code, in the example above this sprocket would be 22. If you need any help with this please us on and we can assist you in sprocket sizing. I have installed my dongle and there is not a noticeable difference? The position of the wheel magnet can affect the switching time of the speed sensor. The wheel magnet may need to be moved slightly to accommodate the correct speed. You can do this by moving the magnet and then riding the bike or spin it in the air. Pedal the bike to 30 mph and your unit should be reading 15mph, if this is out you can adjust the magnet. If you cannot achieve the correct speed you may be using the wrong wheel sized dongle for your bike. My bike is giving error code 102? Two possibilities are.. 1) Your sprocket sizing is giving a 1:1 gear ratio as explained above. 2) There is a loose connection on your dongle or corrosion has taken place on one of the connections, please check all wires are secured and the connections look good. Is it possible to extend the dongle cable? You can use any normal 3.5mm headphone extension cable to extend the dongle to anywhere on the bike. If you are experiencing any problems please Martin For any Bosch Spares, Chain rings, Rear Cassettes etc... Please contact us on our address above. Page 6 of 6

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