Orbea Keram MTB User manual

BLUE PAPER

KERAM

BOSCH GEN4

2020

TECHNICAL MANUAL

BLUE PAPER KERAM BOSCH GEN4 20202 | ORBEA ORBEA | 3TECHNICAL MANUAL

INDEX

GEOMETRY & ERGONOMY 4

TECHNICAL SPECIFICATIONS 6

HEADTUBE AND HEADSET 8

REAR DERAILLEUR 9

PROTECTORS 10

CABLING 13

BOSCH GEN4 MOTOR ASSEMBLY 15

INTERNAL BATTERY ASSEMBLY 16

DUAL BATTERY ASSEMBLY 17

MAINTENANCE 20

ORBEA WARRANTY 22

BLUE PAPER KERAM BOSCH GEN4 20204 | ORBEA ORBEA | 5TECHNICAL MANUAL

SIZE 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

GEOMETRY & ERGONOMY

HEIGHT (CM)HEIGHT (IN)SIZE

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.

* The headtube angle measurement on MTB, Asphalt and Comfort models may change slightly depending on the

travel of the fork specicated.

BLUE PAPER KERAM BOSCH GEN4 20206 | ORBEA ORBEA | 7TECHNICAL MANUAL

TECHNICAL SPECIFICATIONS

FRAME MATERIAL ALUMINUM

INTENDED USE MTB: CROSS COUNTRY, TRAIL

ASPHALT: URBAN, LEISURE

COMFORT: URBAN, LEISURE

SIZES S,M,L,XL

FORK TRAVEL MTB: 100MM O 120MM

ASPHALT: RIGID FORK

COMFORT: 63MM

WHEEL SIZE 700C-29"

MAX. TYRE SIZE 29"X2.4

FORK OFFSET 42MM OR 51MM. DEPENDING ON MODEL

BOTTOM BRACKET MOTOR BOSCH GEN4

HEADSET INTEGRATED 1 1/8-1 1/2

REAR AXLE STANDARD 135MM X 9MM QR

SEATPOST DIAMETER 31.6MM

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

CHAINGUIDE NO

ICGS NO

CABLING INTERNAL (FULL SLEEVE)

LEFT-ROAD CABLING READY YES. ALL CABLES ENTER THE FRAME

ON THE LEFT SIDE

BOTTLE HOLDER 1. ALL SIZES

COMPATIBLE DI2 NO

COMPATIBLE SRAM AXS YES

DRIVETRAIN COMPATIBILITY 10, 11 AND 12 SPEED

COMPATIBILIDAD POTENCIÓMETRO NO

INTERNAL BATTERY YES. IN DOWNTUBE. 400WH OR 500WH. BOSCH POWERPACK

DUAL BATTERY OPTION YES. ONLY AS A COMPLETE OPTION AT THE MOMENT

OF PURCHASE. NOT COMPATIBLE WITH SIZE S FRAME

MOTOR ONLY BOSCH GEN4 AND GEN3

(USES DIFFERENT MOTOR MOUNTING PLATES)

DISPLAY BOSCH PURION

MOTOR ASSEMBLY ANGLE 6,5º

* Not all calipers and rotors in the market are compatible with all frames.

All componets specicated from Orbea have been tested. For aftermarket options, check componentes

dimensions and tolerances before purchasing.

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.

BLUE PAPER KERAM BOSCH GEN4 20208 | ORBEA ORBEA | 9TECHNICAL MANUAL

HEADTUBE AND HEADSET REAR DERAILLEUR

7.5

Ø 46

Ø 52.1

Ø 56

Ø 42

45º

HEADSET 1 1/8-1 1/2 INTEGRATED (INCLUDES TOPCAP AND STARNUT)

KIT Nº: Y0000127 QUANTITY

HEADSET 1 1/8-1 1/2 INTEGRATED 1

QR STANDARD REAR DER. HANGER

01 KIT Nº: Y0000117 QUANTITY

1.1 QR STANDARD REAR DER. HANGER 1

1.2 BOLT M4x9 2

QR DIRECT MOUNT REAR DER. HANGER

13 KIT Nº: Y0000118 QUANTITY

13.1 QR DM REAR DER. HANGER 1

13.2 BOLT M4x9 2

1 1/8 LOWER BEARING ADAPTOR (FOR 1 1/8 STRAIGHT STEERER TUBE FORKS)

ART Nº: 14031591 QUANTITY

1 1/8 LOWER BEARING ADAPTOR 1

1.1

13.1

13.2 1.2

BLUE PAPER KERAM BOSCH GEN4 202010 | ORBEA ORBEA | 11TECHNICAL MANUAL

KERAM 19 SEATPOST CLAMP

02 ART Nº: 11160252 QUANTITY

KERAM 19 SEATPOST CLAMP 1

LEFT CHAINSTAY PROTECTOR

03 KIT Nº: Y0000224 QUANTITY

3.1 LEFT CHAINSTAY PROTECTOR 1

3.2 BOLT M4x25 1

RIGHT CHAINSTAY PROTECTOR

04 KIT Nº: Y0000225 QUANTITY

4.1 RIGHT CHAINSTAY PROTECTOR 1

4.2 BOLT M4x25 1

CHARGING PORT RUBBER PROTECTOR

05 ART Nº: 11000468 QUANTITY

CHARGING PORT RUBBER PROTECTOR 1

BATTERY KEYHOLE RUBBER PROTECTOR

06 ART Nº: 11000467 QUANTITY

BATTERY KEYHOLE RUBBER PROTECTOR 1

BATTERY COVER KIT

07 KIT Nº: Y0000226 QUANTITY

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 1

PROTECTORS

4.1

3.1

7.1

7.4

7.2

7.3

3.2

4.2

1 Nm

7.5

BLUE PAPER KERAM BOSCH GEN4 202012 | ORBEA ORBEA | 13TECHNICAL MANUAL

KERAM BOSCH GEN4 MOTOR PROTECTOR

08 KIT Nº: Y0000223 QUANTITY

8.1 RIGHT MOTOR PROTECTOR 1

8.2 LEFT MOTOR PROTECTOR 1

8.3 BOLT M4x10 4

8.4 BOLT M4x60 1

KERAM 19 CABLEGUIDE KIT

09 KIT Nº: Y0000227 QUANTITY

9.1 RUBBER GROMMET 2mm 22x8 2

9.2 RUBBER GROMMET 5mm 30x10 1

8.2

8.1

8.4

8.3

9.1

9.2

8.3

1 Nm

CABLING

Rear derailleur

Rear brake

Display

Internal battery cable. Use

Bosch Y split cable for double

battery installations.

Speed sensor

Double battery connec-

tion cable. Use Bosch

Y split cable. Cut motor

protector to allow cable

to pass.

BLUE PAPER KERAM BOSCH GEN4 202014 | ORBEA ORBEA | 15TECHNICAL MANUAL

To internal battery´s downtube lower connector.

Battery cable

connector HMI connector: Display

Speed sensor

connector

To front on the bike throught

downtube to display.

Below the left chainstay

to speed sensor xing point.

TORQUE SETTING: 30Nm

ALL CONNECTIONS ARE MADE ON THE NON-DRIVE

SIDE OF THE MOTOR BOSCH GEN4 MOTOR ASSEMBLY

BOSCH GEN4 MOTOR ASSEMBLY KIT

10 KIT Nº: Y0000228 QUANTITY

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

10.6 BOLT M8x55 2

10.7 BOLT M8x50 2

10.8 BOLT M8x16 6

10.9 TOOTHED WASHER M8 4

10.10 SPACER 20.2mm 2

10.1

10.2

10.3

10.4

10.5

10.8

10.6

10.9

10.7 10.8 10.5

10.10

BLUE PAPER KERAM BOSCH GEN4 202016 | ORBEA ORBEA | 17TECHNICAL MANUAL

INTERNAL BATTERY ASSEMBLY

INTERNAL BATTERY ASSEMBLY HARDWARE KIT

BOSCH OR ABUS COMPONENTS NOT INCLUDED.

11 KIT Nº: Y0000229 QUANTITY

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 4

11.1

11.4

11.6

11.3

11.2 11.5

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 specic 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

installation of a powerpack dual battery system.

The installation of these components needs an advanced mechanical and electrical knowledge

and can only be performed by a certied Orbea dealer.

The use of a dual battery requires the electric system to be updated for the correct operation of

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

Keram frames with a Bosch GEN3 motor.

BLUE PAPER KERAM BOSCH GEN4 202018 | ORBEA ORBEA | 19TECHNICAL MANUAL

12.2

12.4 12.8 12.5

12.1

12.6

12.7

12.10

12.9

12.3

DUAL BATTERY ASSEMBLY HARDWARE KIT

BOSCH OR ABUS COMPONENTS NOT INCLUDED

12 KIT Nº: Y0000230 QUANTITY

12.1 U SHAPED TOP BATTERY BRACKET SPACER 1

12.2 BOTTLE HOLDER PLATE DUAL BATTERY 1

12.3 THREADED PLATE BOTTLE HOLDER 1

12.4 BOLT M5x20 2

12.5 BOLT M5x45 2

12.6 M5 SQUARE NUT 2

12.7 M5 TOOTHED WASHER 1

12.8 BOLT M5x15 BOTTLE HOLDER 2

12.9 THREADED BATTERY LOWER MOUNT PLATE 1

12.10 SPACER 6,5mm LOWER BATTERY BRACKET. 1

* Not included. Already on bike or on internal battery hardware kit.

ABUS COMPONENTS REFERENCE DESCRIPTION

POWERPACK LOCK PLUS + KEY

When ordering the new lock, facilitate your abus distributor the

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.

33261 BLO BOS DT2 PLUS

BOSCH COMPONENTS REFERENCE DESCRIPTION

STANDARD BATTERY CABLE 1.270.015.067 Battery Cable Standard

LOWER POWERPACK BATTERY HOLDER LEFT

0.275.007.425 Battery holder kitLOWER POWERPACK BATTERY HOLDER RIGHT

SCREW 3,5x12 (x2)

ALUMINUM BRACKET HOLDER 0.275.007.426 Mounting set for bracket

battery frame

BATTERY BRACKET BOLT (x2)

PLASTIC CASING LOCK TOP

1.270.020.605 Kit plastic casing lock

frame

PLASTIC CASING LOCK BOTTOM

SCREW 3,5x12 (x1)

BOLT M5x12 (x2)

CABLE "Y" DUAL BATTERY 515/430mm

0.275.007.930 Bosch Dual Battery

Y-Adapter kit

CHARGING SOCKET BLANK PLUG (x2)

TAPÓN PIN SOPORTE BATERÍA

It is necessary to cut the motor protector

To allow clearance for the external battery cable.

This manual suits for next models

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