KERAM BLUE PAPER BOSCH GEN4 - Orbea
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TE CHNI CA L MANUAL
BLUE PAPER
KERAM
BOSCH GEN4
2020
2 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 3
INDEX
GEO M ET RY & E R G ON OM Y 4
T EC H N I CAL S P E CI F I CATI ON S 6
H EADT U B E A N D H EA D S ET 8
R EAR DER AI L L E UR 9
P R OT ECTO R S 10
CAB LI NG 13
B O SC H GEN 4 M OTOR AS S E M B LY 15
I NT ER NAL BATTE RY AS S E M B LY 16
DUAL BAT T E RY AS S E M B LY 17
KER AM SU V 2 0 2 1 M OD E LS 18
M AI NT ENAN CE 24
O R B EA WARR A N TY 264 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 5
GEOMETRY & ERGONOMY
SI ZE S -27,5” M-29 ” L-29 ” XL-29 ”
1 - Seat tube (c-t) 400 405 457 515
2 - Top tube (eff) 538 569 603 638.4
3 - Head tube 105 114 133 158
4 - Chainstay 475 475 475 475
5 - Bb height 307 313 313 313
6 - Bb drop 43 63 63 63
7 - Wheelbase 1112 1149 1173 1210
8 - Head angle 67º 67º 68º 68º
9 - Seat angle 73º 73º 73º 73º
10 - Standover heigh 798 825 861 893
11 - Reach 355 375 402 430
12 - Stack 600 636 659 752
13 - Fork length 518 530 530 530
* The headtube angle measurement on MTB, Asphalt and Comfort models may change slightly depending on the
travel of the fork specificated.
HE I GHT (CM) HEIG HT (IN) S IZE
150-165 59.1”-65.0” S-27.5”
165-175 65.0”-68.9” M-29”
175-185 68.9”-72.8” L-29”
185-195 72.8”-76.8” XL-29”
* The sizing measurements are orientative.6 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 7
TECHNICAL SPECIFICATIONS
NOTE: This technical document describes the Keram
models (MTB, Asphalt and Comfort) equipped with
a Bosch Gen4 motor. For 2019 and onwards models
equipped with a previous generation Bosch motor,
consult the technical document Bluepaper Keram 2019
from the manuals section of the Orbea´s website.
FRAME MATERIAL ALUMINUM CHAINGUIDE NO
INTENDED USE MTB: CROSS COUNTRY, TRAIL ICGS NO
ASPHALT: URBAN, LEISURE CABLING INTERNAL (FULL SLEEVE)
COMFORT: URBAN, LEISURE YES. ALL CABLES ENTER THE FRAME
LEFT-ROAD CABLING READY
ON THE LEFT SIDE
SIZES S,M,L,XL
BOTTLE HOLDER 1. ALL SIZES
FORK TRAVEL MTB: 100MM O 120MM
COMPATIBLE DI2 NO
ASPHALT: RIGID FORK
COMPATIBLE SRAM AXS YES
COMFORT: 63MM
DRIVETRAIN COMPATIBILITY 10, 11 AND 12 SPEED
WHEEL SIZE 700C-29"
COMPATIBILIDAD POTENCIÓMETRO NO
MAX. TYRE SIZE 29"X2.4
INTERNAL BATTERY YES. IN DOWNTUBE. 400WH OR 500WH. BOSCH POWERPACK
FORK OFFSET 42MM OR 51MM. DEPENDING ON MODEL
YES. ONLY AS A COMPLETE OPTION AT THE MOMENT
DUAL BATTERY OPTION
BOTTOM BRACKET MOTOR BOSCH GEN4 OF PURCHASE. NOT COMPATIBLE WITH SIZE S FRAME
ONLY BOSCH GEN4 AND GEN3
HEADSET INTEGRATED 1 1/8-1 1/2 MOTOR
(USES DIFFERENT MOTOR MOUNTING PLATES)
REAR AXLE STANDARD 135MM X 9MM QR DISPLAY BOSCH PURION
SEATPOST DIAMETER 31.6MM MOTOR ASSEMBLY ANGLE 6,5º
SEATPOST CLAMP DIAMETER 34,9MM SPECIFIC KERAM 19 FRAME
FRONT DERAILLEUR N/A. 1X ONLY
CHAINRING MAXIMUM SIZE 38T
MAXIMUM CRANK LENGHT 170MM
BRAKES DISCO POST MOUNT *
REAR ROTOR MX. SIZE 180MM
REAR ROTOR MIN. SIZE 160MM * Not all calipers and rotors in the market are compatible with all frames.
All componets specificated from Orbea have been tested. For aftermarket options, check componentes
dimensions and tolerances before purchasing.8 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 9
HEADTUBE AND HEADSET REAR DERAILLEUR
Ø 46
Ø 42
3
45º
1.1
13.2 1.2
13.1
7.5
Ø 52.1
Ø 56
QR STA N DA R D REAR DER. H ANGER
01 KIT Nº: Y0 0 0 0 117 Q UA N T ITY
H EADSET 1 1/ 8 -1 1/ 2 I N T E GR AT E D (INCLUDES TOPCA P AND STARNUT) 1.1 QR STANDARD REAR DER. HANGER 1
KIT N º : Y 0 0 0 0 1 27 QUANT ITY 1.2 BOLT M4x9 2
HEADSET 1 1/8-1 1/2 INTEGRATED 1
QR DIRECT M OUNT REAR DER. H ANGER
1 1/8 LOW ER B EAR I N G A DA PTO R (FO R 1 1 / 8 STR A I G H T ST EERER T U BE FO RKS)
13 KIT Nº: Y0 0 0 0 118 Q UA N T ITY
A RT N º : 1 4 0 3 1 5 9 1 QUANT ITY 13.1 QR DM REAR DER. HANGER 1
1 1/8 LOWER BEARING ADAPTOR 1 13.2 BOLT M4x9 21 0 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 11
PROTECTORS
KERA M 1 9 S EATPOST C LAM P
02 ART Nº: 1116 0 252 Q UA N T ITY
2 KERAM 19 SEATPOST CLAMP 1
LEFT CHA IN STAY PROTECTOR
03 KIT Nº: Y0 0 0 0 224 Q UA N T ITY
3.1 LEFT CHAINSTAY PROTECTOR 1
3.2 BOLT M4x25 1
7.4
7.5
7.2
7.3
RIGHT CHA INSTAY PROTECTOR
04 KIT Nº: Y0 0 0 0 225 Q UA N T ITY
4.1 RIGHT CHAINSTAY PROTECTOR 1
4.2 BOLT M4x25 1
CHA RGIN G P O RT RUBBER PROTECTOR
7.1 05 ART Nº: 110 0 0 46 8 Q UA N T ITY
CHARGING PORT RUBBER PROTECTOR 1
4.1
20
1 Nm 4.2
BATTERY KEYH OLE RUBBER PROTECTOR
06 ART Nº: 110 0 0 46 7 Q UA N T ITY
6
5 BATTERY KEYHOLE RUBBER PROTECTOR 1
3.1
BATTERY COVER KIT
20 07 KIT Nº: Y0 0 0 0 226 Q UA N T ITY
1 Nm 3.2
7.1 BATTERY COVER KERAM 19 BLACK 1
7.2 BATTERY COVER LOCK MALE 1
7.3 BATTERY COVER LOCK FEMALE 1
7.4 WASHER 4,5mm 1
7.5 WASHER M6 11 2 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 13
CABLING
8.2
Rear derailleur
9.1
8.1
M4
1 Nm 9.2
8.3
8.4
Display
Rear brake
9.1
Double battery connec-
tion cable. Use Bosch
Y split cable. Cut motor
protector to allow cable
to pass.
M4
1 Nm 8.3
Internal battery cable. Use
Bosch Y split cable for double
battery installations.
Speed sensor
K ER AM B OSCH G EN4 M OTO R P R OT E CTO R KERA M 1 9 CABLEGUIDE KIT
08 KI T Nº : Y 0 0 0 0 22 3 QUANT ITY 09 KIT Nº: Y0 0 0 0 227 Q UA N T ITY
8.1 RIGHT MOTOR PROTECTOR 1 9.1 RUBBER GROMMET 2mm 22x8 2
8.2 LEFT MOTOR PROTECTOR 1 9.2 RUBBER GROMMET 5mm 30x10 1
8.3 BOLT M4x10 4
8.4 BOLT M4x60 11 4 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 15
ALL CONNECTIONS ARE MADE ON THE NON-DRIVE
SIDE OF THE MOTOR BOSCH GEN4 MOTOR ASSEMBLY
Below the left chainstay
to speed sensor fixing point.
10.1
To front on the bike throught
downtube to display.
To internal battery´s downtube lower connector.
10.2
10.3
10.9 10.5
10.8
10.4 10.7 10.8
10.5
10.6
10.8
10.10
10.8
TORQUE SETTING: 30Nm
BOS CH GEN 4 M OTOR ASSEM BLY KIT
10 KIT Nº: Y0 0 0 0 228 Q UA N T ITY
10.1 BOSCH G4 ASSEMBLY PLATE LONG LEFT 1
10.2 BOSCH G4 ASSEMBLY PLATE LONG RIGHT 1
10.3 BOSCH G4 ASSEMBLY PLATE SHORT LEFT 1
10.4 BOSCH G4 ASSEMBLY PLATE SHORT RIGHT 1
10.5 NUT M8 4
Battery cable
connector HMI connector: Display 10.6 BOLT M8x55 2
10.7 BOLT M8x50 2
10.8 BOLT M8x16 6
Speed sensor
connector 10.9 TOOTHED WASHER M8 4
10.10 SPACER 20.2mm 21 6 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 17
INTERNAL BATTERY ASSEMBLY DUAL BATTERY ASSEMBLY
The complete external battery connection kit is only available as an option when purchasing a
keram from Orbea.
For bikes that were purchased with the internal battery only, Orbea will facilitate the compo-
nents that are Orbea´s own and specific to the Keram frame for the installation of the external
battery. These items are included in the kit Y0000230.
The electric components, like cables and powerpack battery brackets, as well as the locks, may
be purchased through a Bosch or Abus distributor. These components are in the next page.
Contact your Abus and Bosch ebike dealer to know the exact list of components needed for the
11.6
installation of a powerpack dual battery system.
11.3
The installation of these components needs an advanced mechanical and electrical knowledge
and can only be performed by a certified Orbea dealer.
The use of a dual battery requires the electric system to be updated for the correct operation of
11.4
all components. This update must be carried out by a Bosch ebike dealer.
The dual battery option is not compatible with size S Keram frames.
The aftermarket assembly of the dual battery option is only compatible with Keram frames
equipped with a Bosch Gen4 motor. Orbea cannot guarantee the components compatibility on
11.1
Keram frames with a Bosch GEN3 motor.
11.5
11.2
I N TER N AL BAT T ERY AS S E M BLY H A R DWA R E K I T
BOSCH OR ABUS COMPONENTS NOT INCLUDED.
11 KI T Nº : Y 0 0 0 0 22 9 QUANT ITY
11.1 THREADED BATTERY LOWER MOUNT PLATE 1
11.2 SPACER 6,5mm LOWER BATTERY MOUNT 1
11.3 BOLT M5x18 2
11.4 BOLT M5x30 2
11.5 M5 SQUARE NUT 2
11.6 RUBBER ALLEN BOLT HEAD COVER 41 8 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 19
12.4 12.5
12.8
12.1
12.10
It is necessary to cut the motor protector
To allow clearance for the external battery cable.
12.7
12.2
12.9
12.3 12.6 ABUS COMPONENTS REFERENCE DESCRIPTION
POWERPACK LOCK PLUS + KEY
When ordering the new lock, facilitate your abus distributor the
33261 BLO BOS DT2 PLUS
Key number on your wild fs so the new lock is made to match the key,
Enabling you to use the same key for both batteries.
DUAL BAT T E RY ASSE M B LY H A R DWA R E K I T
BOSCH COMPONENTS REFERENCE DESCRIPTION
BOSCH OR ABUS COMPONENTS NOT INCLUDED
STANDARD BATTERY CABLE 1.270.015.067 Battery Cable Standard
12 KI T Nº : Y 0 0 0 0 2 3 0 QUANT ITY LOWER POWERPACK BATTERY HOLDER LEFT
12.1 U SHAPED TOP BATTERY BRACKET SPACER 1
LOWER POWERPACK BATTERY HOLDER RIGHT 0.275.007.425 Battery holder kit
12.2 BOTTLE HOLDER PLATE DUAL BATTERY 1
SCREW 3,5x12 (x2)
12.3 THREADED PLATE BOTTLE HOLDER 1
ALUMINUM BRACKET HOLDER Mounting set for bracket
12.4 BOLT M5x20 2 0.275.007.426
BATTERY BRACKET BOLT (x2) battery frame
12.5 BOLT M5x45 2
PLASTIC CASING LOCK TOP
12.6 M5 SQUARE NUT 2
PLASTIC CASING LOCK BOTTOM Kit plastic casing lock
12.7 M5 TOOTHED WASHER 1 1.270.020.605
SCREW 3,5x12 (x1) frame
12.8 BOLT M5x15 BOTTLE HOLDER 2
BOLT M5x12 (x2)
12.9 THREADED BATTERY LOWER MOUNT PLATE 1
CABLE "Y" DUAL BATTERY 515/430mm
12.10 SPACER 6,5mm LOWER BATTERY BRACKET. 1 Bosch Dual Battery
CHARGING SOCKET BLANK PLUG (x2) 0.275.007.930
Y-Adapter kit
* Not included. Already on bike or on internal battery hardware kit. TAPÓN PIN SOPORTE BATERÍA2 0 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 2 1
KERAM SUV 2021 MODELS Follow the steps below for the assembly of the front rack
FRONT RACK ASSEMBLY. and front light on Keram SUV models when taking the bi-
cycle out of the box.
INFORMATION FOR DEALERS. 01
Keram SUV 2021 models are equipped with Orbea original Remove the protective packaging from the front light.
rear and front racks, Lezyne lights and mudguards.
02
Diassemble the stem from the bicycle and remove the car-
dboard spacer from the fork steerer tube.
03 04
Install the front rack on the fork steerer tube and install Install the front light onto the rack.
the stem.
Adjust the headset preload and tighten the stem bolts to
the recommended torque setting (5-6Nm)
Do not install any extra headset spacers. The front
rack functions as all the headset spacers allowed
for Keram SUV.
05
Fasten the front light cable to the rack with zipties and
introduce any excess cable into the frame.
FRONT RACK KERAM SUV REAR RACK KERAM SUV
MATERIAL ALUMINUM MATERIAL ALUMINUM
LOAD LIMIT 15kg LOAD LIMIT 25kg
The Bosch front lights cable and the Lezyne
light are fitted with a JST connector for a be-
tter interface.
If it is necessary to replace the lights cable or
the front light, contact Orbea.22 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 2 3
REAR MUDGUARD REAR RACK AND MUDGUARD
AND RACK ASSEMBLY
The Keram SUV rear mudguard is specific for rear rack assemblies. The mud-
guard blade is attached to the rear rack tubes.
The Keram SUV mudguard set and racks are only available as a replacement
item through an Orbea dealer due to breakage or a warranty claim.
FRONT MUDGUARD
The front mudguard rods attach to the fork differently de- - On Keram SUV 20 models with Suntour XCR34 forks, the
pending on the Keram models. rods attach directly to the fork lowers with the hardware
provided.
- On Keram SUV 30 with Suntour XCR32 forks, the rods
attach to the fork lowers using clamp attachments.
Rear mudguard attachment points.
Rear rack attachment points.24 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 2 5
MAINTENANCE
Orbea products are carefully designed to be long-lasting, TEST RIDE Take a quick ride up and down the street to
efficient and easy to maintain. The carbon and aluminum make sure your bike is shifting and braking properly. Lis- A FTER A CRASH OR IM PACT
frames on the Keram are extremely corrosion-resistant. ten for unusual noises.
However, your Orbea bicycle needs regular maintenance Falling is part of riding and it’s impossible to avoid minor
of its components in order to work properly and to ensure accidents. If you crash your Keram, please make sure you
are okay and seek medical attention if necessary. If you
their longevity.
4 ) B EA R IN GS are not injured, you should check your bike before con-
tinuing:
1 ) K EEP YOUR KE R AM C LEA N Bearings are one element subject to wear and tear. They
must be in good condition to ensure that the other parts 1) Inspect your frame and components for damage.
Washing your bike with mild soap and water will keep you of the bicycle work correctly: on the wheels, the steering Do not ride your bike if any problems are detected.
looking stylish and allow you to check the condition of the column and the bottom bracket.
frame and components. Don’t use high water pressure and
avoid spraying water into bearings or frame tubes. Citrus Regularly check to make sure that the bearings turn freely WHAT TO LOO K FOR
degreasers are biodegradeable and do a great job of re- in their housing and there are no signs of lateral play. Bea-
mo-ving dirty grease from gears and chain. rings that do not turn properly or that have any lateral play Inspect Frame and fork for evidence of cracking or ben-
must be replaced immediately in order to prevent wear ding. If cracks are discovered, discontinue use imme-
and tear to the parts of the frame. Very damp weather dia-tely.
2 ) K EEP YOUR KER AM LU BE D conditions can cause the bearings to wear out faster. Avoid
washing your bicycle with pressurized water hoses. If you Check the drivetrain and spin the wheels to make sure
Once your bike is clean, it’s a good time to put fresh lube have any questions, take your bicycle to an Orbea dealer components are operating correctly. If you discover
on the chain. Use only enough to get inside the links and for correct diagnosis and maintenance. da-mage to your components, discontinue use immedia-
wipe off any excess because it will attract dirt. Headset tely.
and pivot bearings should be inspected every few months
for smoothness and to ensure that the seals are intact and 5 ) BO S C H EBIKE ELECTRIC SYSTEM Even if you don’t find any damage, pay careful attention
lube is clean. to the sound of your bike when you continue riding. Un-
Ebikes´ electric systems use complex electronic compo- usual noises can be caused by cracks or other problems.
nents that require your attention. Always read the availa- A well-maintained bike will be quiet and free of creaks or
3 ) I NSP E CT YOUR KER A M B E F O R E ble documentation before using your ebike and follow the squeaks. Investigate and locate the source of any new
recommended use and maintenance instructions. noises.
YOU R I D E This documentation will allow you to get the maximum
performance out of your ebike. 2) Bring your bike to your Orbea dealer for profes-
To know more about the Bosch system on your Keram, sio-nal inspection. Some damage can only be detected
Do a quick check before every ride to make sure your bike
go to: by disassembling the bike to check for cracks or other
is in excellent condition. It is very common to discover
small issues at home that can become big problems on the signs of stress.
https://www.bosch-ebike.com/
trail. CHAIN Is the chain dirty, noisy or dry? Clean and lube
your chain before riding. BRAKES Check your brakes to A crash or impact can put extraordinary stress on your
make sure they are working correctly. Check for missing/ bike and components, causing them to fail or to fa-ti-
loose caliper and rotor bolts. TIRES Look for damage to gue prematurely. Failure can happen suddenly with
the sidewalls of your tires. Check and adjust tire pressu-re. no warning, causing loss of control, serious injury or
WHEELS Spin the wheels and look for wobbles, check death.
for loose or broken spokes. Check quick release levers
to make sure they are functioning properly. FRONT END
Stand over the saddle, pull on the brakes and rock the bike
back and forth. Feel for any play or knocking that might
indicate a loose headset, loose brake rotors or calipers, or
worn fork bushings.2 6 | O R BEA TE CH N I CA L M A N UA L B LUE PA P E R K E R A M B OS C H GE N4 2 02 0 O RB EA | 27
ORBEA WARRANTY ADDITIONAL INFORMATION
The constant effort we make every day to produce the See the full description of the coverage and the Lifetime ORBEA participates actively on facebook and Twitter with
highest quality bicycles enables us to offer the following Warranty conditions at:
WA RRA N TY CLAIM PROC ESS our fantastic global community of riders. Looking to find
warranty and coverage conditions: https://www.orbea.com/int-en/warranty-benefits/ spots to ride or plan a vacation? Someone will have the
All warranty claim processes must be processed through
answers:
an Orbea dealer, who will provide the company with the
LEGAL WAR R ANTY R E GI ST E R YOU R BICYCLE necessary documentation for the diagnosis of said claim.
Orbea guarantees its products by law for a period of 2 In order to benefit from the extension of the Orbea Life-
The dealer will inform the customer of the decision made
by Orbea.
FAC EBOOK
www.facebook.com/OrbeaBicycles
years or whatever has been stipulated as the legal warran- ti-me Warranty, register your bike within the first 30 days
ty period in the country where the purchase was made, to of having purchased it at www.orbea.com
the original owner of the bicycle/component.
BOS CH EBIKE PRODUCTS TW ITTER
01. REGISTER YOUR ACCOUNT www.twitter.com/Orbea/
Bosch ebike components are covered by a two year
This warranty covers Orbea products against manufac-
warranty from the moment of purchase. Consult the
tu-ring defects and/or lack of conformity and guarantees
the repair or replacement of the defective product at no
complete warranty terms and conditions on https://www. YOUTUBE
bosch-ebike.com/ Visit our Orbea Channel on You Tube for a variety of helpful
cost to the affected customer. Likewise, this warranty also
co-vers paint, varnish and corrosion defects on all frames 02. REGISTRATION NUMBER setup and tech videos:
For any question or claim about the Bosch system on your www.youtube.com/user/OrbeaBicycles
and rigid forks assembled on our bicycles during the pe-
Wild HT, contact your Orbea dealer.
riod specified in the first paragraph of this warranty.
This warranty does not cover in any case damage derived
INSTAGRAM
www.instagram.com/orbeabicycles
from misuse or the lack of maintenance, or from the nor-
mal wear and tear of perishable parts, such as, but not
limited to: seals, bearings, handlebar tape, spokes, hub,
threads, tires, seat, etc.
ORBEA C ONTENT
View and download photos, videos and documents.
content.orbea.com/us-en/
See the full description of the coverage and the legal
warranty conditions at:
https://www.orbea.com/int-en/warranty-benefits/ 03. WHERE TO FIND YOUR NUMBER BLOG ORBEA
www.orbea.com/es-es/blog/
OR BEA LI FET I ME WARR A N TY
2 YOUR ORBEA DEALER
As a complement to the legal warranty, Orbea offers the Our dealers are experts and should be able to assist you
original buyer of the bicycle, under the condition of ha- with setting up and maintaining your Orbea bicycle. A
ving registered their bicycle on the Orbea website within a com-plete listing of Orbea dealers and distributors can be
period of 30 days following its purchase, the Orbea Li-fe- located on our website:
time Warranty, which covers the frames and rigid forks 1 3 www.orbea.com/us-en/dealers/?country=INT
we assemble on our bicycles, with no time limit, against
manufacturing defects.
SUPPORT
This warranty extends the original period of coverage For technical questions about Orbea products, write to:
1 2 3
against pain, varnish or corrosion defects on our frames support@orbea.com
and rigid forks for one additional year after the end of the
legal warranty period. For any other question:
orbea@orbea.comWWW.OR B EA .COM
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