VOLspeed 4 Bosch eBike Tuning Speed Unlock Kit User Manual

1. Introduction

The VOLspeed 4 Bosch eBike Tuning Speed Unlock Kit is designed to enhance the performance of your Bosch eBike motor. This module allows you to fully unlock the motor's speed capabilities, providing a more dynamic and enjoyable riding experience. It integrates seamlessly with your eBike's system, ensuring accurate data display and maintaining essential functionalities.

Figure 1: The VOLspeed 4 Bosch tuning module, showing its compact black housing and color-coded wiring with connectors.

2. Compatibility

The VOLspeed 4 tuning module is compatible with a wide range of Bosch eBike motors and displays. Please review the compatibility details below to ensure your eBike is supported.

• Compatible Motors: All BOSCH motors from 2013 to 2022, including Active Line, Active Line Plus, Performance Line, and Performance CX Line. This includes 4th generation motors (MY2020) with anti-tuning software.
• Firmware: Compatible with the latest Bosch 2020 FW upgrade (increased torque up to 85NM).
• NOT Compatible: The module is NOT compatible with the 2022 (new smart system) BES3.

Figure 2: Visual guide to compatible Bosch displays (Nyon 2, Kiox, Intuvia, Purion) and incompatible systems (Kiox 300, Kiox 500, Intuvia 100, LED Remote, Purion 200, Mini Remote, System Controller, Rim Magnet/Felgenmagnet, ABS, Bosch Smart System).

3. Key Features

• Speed Unlock: Fully unlocks the motor for speeds up to 45 km/h.
• Adjustable Speed Limit: Set your own speed limit to manage battery consumption or customize your ride.
• Easy Configuration: All settings can be easily adjusted using the eBike's display control buttons.
• Automatic Deactivation: The tuning is always deactivated after the bike is powered on, ensuring compliance with regulations when starting.
• Accurate Data: Correct total mileage of the bike is maintained, even after removing the tuning module, as mileage is tracked in the motor control. Range calculation remains accurate with tuning active. Battery percentage remains accurate.
• Dynamic Mode: Features a 'softer control behavior' (dynamic mode) which reduces the abrupt motor cut-off, providing a more pleasant riding experience and consistent pedal stroke.
• Workshop Mode: Allows for complete deactivation of the module, useful for workshop visits or diagnostics.
• Compact Design: Approximately 40% smaller than previous models for improved fit within the motor compartment.
• Durable Construction: Electronics are fully encapsulated in the housing, making them absolutely waterproof.
• Simple Installation: Does not require a diagnostic tool for installation. Features color-coded connectors for easy matching to motor wiring.

4. Installation Guide

The VOLspeed 4 module is designed for straightforward installation. Follow these steps carefully.

4.1. Preparation

1. Ensure your eBike is powered off and the battery is removed for safety.
2. Locate the motor compartment, typically under the left motor cover. You will need an Allen key to remove the cover.

4.2. Disconnecting Motor Cables

Identify the connectors on your Bosch motor. The VOLspeed module connects to specific points. You will find color-coded connectors (black with 4 wires and grey with 2 wires).

Figure 3: Disconnect the connectors marked in green. Pay attention to the specific connectors for Motor Gen. 2 (Active Line, Performance-Line (CX) until 2019), Motor Gen. 3 (Active Line from 2020, Active Line Plus from 2018, Performance Line from 2020), and Motor Gen. 4 (Performance Line CX from 2020).

ATTENTION: Reduce the risk of confusion.

In addition to the diagram, pay attention to the color of the small plug. Disconnect ONLY the grey speed sensor plug. Blue is for the front light, and black is for the rear light; do not disconnect these.

4.3. Connecting the VOLspeed Module

1. Plug the VOLspeed tuning module into the now free sockets on the motor. The module's connectors are color-coded to match the motor's wiring for easy identification.
2. Connect the previously unplugged cables from the motor to the corresponding connections on the VOLspeed tuning module. Ensure all connections are secure and fully seated.

Figure 4: Hands demonstrating the connection of the VOLspeed module's color-coded wires to the eBike motor's wiring harness.

4.4. Securing the Module

Once connected, carefully route the cables and position the VOLspeed module within the motor compartment. Ensure it is not pinched or obstructing any moving parts. The compact size of the module facilitates easier placement.

Replace the motor cover and secure it with the screws removed earlier.

4.5. Installation Videos

For a detailed visual guide, please refer to the official installation videos:

5. Operation

The VOLspeed 4 module is designed for intuitive operation via your eBike's existing display controls.

5.1. Activating and Deactivating Tuning

Upon powering on your eBike, the tuning module is automatically deactivated. To activate the tuning and unlock the speed limit, refer to the specific button combinations or menu options on your eBike's display as detailed in the VOLspeed quick start guide (usually provided with the product). The tuning can be deactivated again through the same process or by powering off the bike.

5.2. Setting the Speed Limit

You can set a custom speed limit up to 45 km/h directly through your eBike's display. This allows for fine-tuning your ride experience and optimizing battery usage. Consult the VOLspeed quick start guide for the exact steps to adjust this setting.

5.3. Dynamic Mode (Softer Control Behavior)

The dynamic mode feature reduces the abrupt motor cut-off that can occur when reaching the standard speed limit. This provides a smoother transition and a more natural pedaling feel. This mode can be enabled or disabled via the display settings.

5.4. Workshop Mode

For maintenance, diagnostics, or compliance during service, the module can be fully deactivated using the workshop mode. This ensures that the eBike operates as if no tuning module is installed. Refer to the quick start guide for instructions on entering and exiting workshop mode.

6. Maintenance

The VOLspeed 4 module is designed to be maintenance-free due to its robust, waterproof encapsulation. However, general care for your eBike will help ensure the longevity of the module and its connections:

• Keep the motor compartment clean and free of excessive dirt or debris.
• Avoid exposing the module or its connections to extreme physical impact.
• If you need to access the motor compartment, ensure the eBike is powered off and the battery is removed before opening.

7. Troubleshooting

If you encounter any issues with your VOLspeed 4 module, consider the following common solutions:

• Tuning Not Activating:
  • Ensure the module is correctly installed and all connectors are securely seated. Refer to the installation guide (Section 4).
  • Verify that your eBike's motor and display are compatible with the VOLspeed 4 module (Section 2).
  • Check if the module is in "Workshop Mode" and deactivate it if necessary.
• Incorrect Speed/Mileage Display:
  • While the module is designed to maintain accuracy, ensure no other modifications are interfering with the speed sensor.
  • If the issue persists, temporarily remove the module to see if the display returns to normal, which may indicate a module-related issue.
• Motor Error Codes:
  • In rare cases, an eBike system might display an error code. This can sometimes be resolved by ensuring the module is correctly installed and not causing any electrical interference.
  • If an error code appears, try deactivating the tuning or entering workshop mode. If the error persists, consult your eBike's manual or a certified Bosch service center.
• Module Not Powering On:
  • Check all connections for proper seating.
  • Ensure the eBike battery is charged and properly installed.

If these steps do not resolve the issue, please contact VOLspeed customer support for further assistance.

8. Specifications

9. Warranty and Support

VOLspeed is committed to customer satisfaction. For any questions, technical assistance, or warranty inquiries regarding your VOLspeed 4 Bosch tuning module, please do not hesitate to contact the manufacturer directly or your point of purchase.

Please retain your proof of purchase for warranty claims.