Trek Diamant Zouma+ S Service Information

Brand: Trek

Model: Diamant Zouma+ S

Type: Service Information

This manual is also suitable for

Trek

Super Commuter+

Diamant

Zouma+

Dealer Service Information

2017

Trek Super Commuter+ 8/ 9/ 8S/ 9S

Diamant Zouma+ (/S /Elite /Elite S)

Table of Contents

1. Overview bicycle conﬁgurations .....................................................................................................................................................................3

2. Walk around ..........................................................................................................................................................................................................4

2.1 Show view – Colors and drive systems ..................................................................................................................................................4

2.2 Front/Rear view ...........................................................................................................................................................................................5

2.3 Side view ........................................................................................................................................................................................................5

2.4 Cockpit ...........................................................................................................................................................................................................6

3. Technical details ...................................................................................................................................................................................................7

3.1 Frame 7

3.1.1 Frame sizes ........................................................................................................................................................................................7

3.1.2 Use Condition ...................................................................................................................................................................................7

3.1.3 Drop-outs ..........................................................................................................................................................................................7

3.2 Speciﬁc parts ................................................................................................................................................................................................7

3.2.1 Speciﬁc parts - overview .................................................................................................................................................................7

3.2.2 Speciﬁc parts – photos ....................................................................................................................................................................8

3.3 Model and sales region speciﬁc components ......................................................................................................................................9

3.3.1 Conﬁguration depending parts - overview ...................................................................................................................................9

3.3.2 Conﬁguration depending parts - photos .....................................................................................................................................10

3.4 Additional parts on 45 km/h EU-models ............................................................................................................................................. 11

3.4.1 Additional parts on 45 km/h EU-models - overview ................................................................................................................ 11

3.4.2 Additional parts on 45 km/h EU-models – photos ................................................................................................................... 12

3.5 Bosch eBike Assist system ...................................................................................................................................................................... 12

3.5.1 Bosch eBike Assist system - overview ......................................................................................................................................... 13

3.5.2 Bosch eBike Assist system – photos ............................................................................................................................................ 13

3.6 Drive train .................................................................................................................................................................................................... 14

3.7 Brake system ...............................................................................................................................................................................................14

3.7.1 Brake system – overview ............................................................................................................................................................... 14

3.7.2 Brake system – details ...................................................................................................................................................................14

3.8 Fenders .........................................................................................................................................................................................................14

3.8.1 Front fender attachment ...............................................................................................................................................................14

3.8.2 Rear fender attachment ................................................................................................................................................................ 15

3.9 Rear rack ...................................................................................................................................................................................................... 16

3.9.1 Rack – design and application ...................................................................................................................................................... 16

3.9.2 Rack – maximum allowed load .................................................................................................................................................... 16

3.10 Cable routing .............................................................................................................................................................................................. 16

3.10.1 Routing of the front brake cable at the fork ...............................................................................................................................16

3.10.2 Routing of the rear brake and shifter cables .............................................................................................................................. 17

3.10.3 Routing of electrical wiring to the front of the bicycle .............................................................................................................. 17

3.10.4 Routing of electrical wiring to the rear of the bicycle ............................................................................................................... 17

3.10.5 Cable routing – photos .................................................................................................................................................................. 18

3.10.6 Cable routing – technical drawings ............................................................................................................................................. 19

3.11 Tires ..............................................................................................................................................................................................................22

3.11.1 Tire size ............................................................................................................................................................................................22

3.11.2 Tire pressure ...................................................................................................................................................................................22

3.11.3 Tires speciﬁcations .........................................................................................................................................................................22

4. Electrical speciﬁcations ...................................................................................................................................................................................23

4.1 Light conﬁgurations ..................................................................................................................................................................................23

4.1.1 Lights on EU 25 km/h models ......................................................................................................................................................23

4.1.2 Lights on US 28 mph models .......................................................................................................................................................23

4.1.3 Lights on 45 km/h models with EU-Type Approval ..................................................................................................................23

4.1.4 Lights – photos .............................................................................................................................................................................. 24

4.2 Electric diagram of lights ........................................................................................................................................................................ 25

4.2.1 Electric diagram of lights on non EU-Type Approval bicycles ................................................................................................. 25

4.2.2 Electric diagram of lights on EU-Type Approval bicycles ........................................................................................................ 26

4.2.3 Electrical connections to the Bosch drive unit ............................................................................................................................27

5. Operating instructions .................................................................................................................................................................................... 28

5.1 Charging the battery ................................................................................................................................................................................ 28

5.2 Battery removal/installation .................................................................................................................................................................. 28

5.2.1 Battery removal ............................................................................................................................................................................. 28

5.2.2 Battery installation ....................................................................................................................................................................... 29

5.3 Operating the Bosch eBike assist system ........................................................................................................................................... 29

5.4 Switching the lights On/Of .................................................................................................................................................................... 29

5.4.1 Switching the lights On/Off on Non – EU-Type Approval bicycles........................................................................................ 29

5.4.2 Switching the lights On/Off on models with EU-Type Approval ........................................................................................... 30

5.5 Panniers ....................................................................................................................................................................................................... 30

6. Bicycle speciﬁc maintenance......................................................................................................................................................................... 30

6.1 Battery rail ................................................................................................................................................................................................... 31

6.1.1 Adjusting the battery rail position ............................................................................................................................................... 31

6.1.2 Replacing the battery rail ..............................................................................................................................................................32

6.2 Replacing the battery lock .......................................................................................................................................................................33

6.3 Replacing the battery docking ............................................................................................................................................................... 34

6.4 Drop-out mounting ...................................................................................................................................................................................35

6.5 Replacing the front fender ...................................................................................................................................................................... 36

6.6 Replacing the rear fender ....................................................................................................................................................................... 36

6.6.1 Needed tools and parts ................................................................................................................................................................ 36

6.6.2 Removing the old fender and the components ..........................................................................................................................37

6.6.3 Marking holes on the replacement fender................................................................................................................................. 38

6.6.4 Drilling holes in the replacement fender .................................................................................................................................... 38

6.6.5 Mounting the new fender ............................................................................................................................................................ 39

6.7 Rack mounting .......................................................................................................................................................................................... 39

6.8 Mounting the drive unit ..........................................................................................................................................................................40

6.8.1 Replacing the drive unit................................................................................................................................................................40

6.8.2 Drive unit mounting - technical drawing .................................................................................................................................... 41

7. Spare parts .......................................................................................................................................................................................................... 42

7.1 Spare parts - bicycle ................................................................................................................................................................................ 42

7.2 Spare parts - Bosch eBike System ........................................................................................................................................................ 43

7.3 Disposal ...................................................................................................................................................................................................... 43

7.3.1 Disposal of electrical components .............................................................................................................................................. 43

7.3.2 Disposal of batteries ..................................................................................................................................................................... 43

8. RIDE+ Owner’s manuals .................................................................................................................................................................................44

8.1 RIDE+ Owner’s manuals - content and languages...........................................................................................................................44

8.1.1 RIDE+ Owner’s manual for bicycles sold in Europe..................................................................................................................44

8.1.2 RIDE+ Owner’s manual for bicycles sold in the US .................................................................................................................. 44

8.2 RIDE+ Owner’s manuals - overview MY2017 ...................................................................................................................................44

1. Overview bicycle conﬁgurations

The bicycles with the Trek ‘SC-frame’ are available in these conﬁgurations, depending on region:

Model Gear

Maximum

speed

EU - Type

Approval Region

Diamant Zouma+ 11 speed derailleur 25 km/h No Germany, Austria, Switzerland

Zouma Elite+ NuVinci N380 SE 25 km/h No Germany, Austria, Switzerland

Zouma+ S 11 speed derailleur 45 km/h Yes Germany, Austria, Switzerland

Zouma Elite+ S NuVinci N380 SE 45 km/h Yes Germany, Austria, Switzerland

Trek Super Commuter+ 8 11 speed derailleur 25 km/h No EU

Super Commuter+ 9 NuVinci N380 SE 25 km/h No EU

Super Commuter+ 8S 11 speed derailleur 45 km/h Yes EU

Super Commuter+ 9S NuVinci N380 SE 45 km/h Yes EU

Super Commuter+ 8S 11 speed derailleur 28 mph No US/Canada

2. Walk around

2.1 Show view – Colors and drive systems

Trek Diamant

IGH IGH

Super Commuter 9 - 9S Diamant Zouma Elite+ (S)

Derailleur Derailleur

Super Commuter 8 - 8S Diamant Zouma+ (S)

2.2 Front/Rear view

Front view Rear view

* Note.

Type of front/taillight and presence of the mirror is depending on the bicycles’ conﬁguration and region.

2.3 Side view

Side view (IGH)

Side view (Derailleur)

2.4 Cockpit

Variant with Bosch Purion display and IGH shifter

Variant with Bosch Purion display and derailleur shifter

Notes.

• The mirror is mandatory for Speed Pedelecs in Europe according to the European Type Approval

(position: above handlebar).

• The high beam light switch is only present on bicycles with the Supernova M99 Pro head light.

3. Technical details

3.1 Frame

The bicycles are equipped with a specially designed frame for a center Bosch drive unit and have a semi integrated

battery pack. The frames are adapted to accommodate the brake and shifter cables and electric wiring inside. The

bicycle frames comply with the ISO 4210 norm.

3.1.1 Frame sizes

The Trek Super Commuter+ and Diamant Zouma+ bicycles are available in four frame sizes:

45, 50, 55 and 60cm. The frame sizing is virtual. As virtual size, the actual seat tube length is 5cm shorter, to

create a better stand over.

3.1.2 Use Condition

There are many types of bicycles, and each is designed for a speciﬁc Use Condition.

This bicycle is designed for Use Condition 1; “Riding on a paved surface where the tires are always on the ground”.

• The total weight limit (rider and luggage) for this bicycle is 136kg / 300lb.

• The maximum weight of the rider is 125kg / 275lb).

• The maximum allowed load on the rack is 7,5kg / 16,5lb per side; in total 15kg / 33lb.

3.1.3 Drop-outs

The frame is designed to mount two types of drop-outs; IGH drop-outs or derailleur drop-outs.

If the IGH drop-outs are mounted (on bicycles with IGH), the slotted holes in the frame can be used to adjust the

dropouts for proper chain tension.

Slotted holes to adjust the chain tension

3.2 Speciﬁc parts

3.2.1 Speciﬁc parts - overview

All bicycles with the ‘SC-frame’ are equipped with the following special features:

• Semi integrated battery • Motor armor

• Battery rail • Cover on electrics drive unit

• Battery lock • Chain guide on motor

• Charger plug cover • Chain stay protector

• Bosch Purion display • Rear rack

• Special spacers on the rear fender • Brake cable mounting at fork

• Fender end pieces • Cable plug down tube left & right

3.2.2 Speciﬁc parts – photos

Semi integrated battery Battery rail Battery lock

Battery charge plug Bosch Purion display Special spacers on the rear fender

Fender end piece Motor armor Chain guide on motor

Cover on drive unit Chain stay protector Rear rack

Cable plug down tube

left & right

3.3 Model and sales region speciﬁc components

3.3.1 Conﬁguration depending parts - overview

Depending on the conﬁguration and region, the bicycles are equipped with a selection of these parts:

• Front light: • Rear derailleur protector*

Supernova E3 Mini2 • Rear hub:

Supernova M99 Pure+ 11 speed rear derailleur

Supernova M99 Pro (daytime running light,

low beam and high beam

NuVinci N380 SE gear hub

• Shifter:

• Taillight: Shimano trigger shifter

Supernova E3 NuVinci roller shifter

Supernova M99 (with built-in brake light and

license plate light) *On bicycles with rear derailleur.

3.3.2 Conﬁguration depending parts - photos

Supernova E3 Mini2 Supernova M99 Pure+ Supernova M99 Pro

Supernova E3 taillight +

rear reﬂector

Supernova M99 taillight +

rear reﬂector

Derailleur protector

11 speed derailleur NuVinci N380 SE

Shimano trigger shifter NuVinci roller shifter Cable mounting on chain stay

Derailleur (A)/ IGH (B)

3.4 Additional parts on 45 km/h EU-models

3.4.1 Additional parts on 45 km/h EU-models - overview

The 45 km/h fast electric bicycle EU-models comply with EU-Type Approval (e1-2002-24-0727-00) for MY2017

and to this aim are additionally equipped with the following bicycle parts*:

• Front light with daytime running light and high

beam

• Brake light switches on both brake levers

• Speed bicycle brake levers

• Light switch (for high beam) • Rear view mirror (position: above handlebar)

• LED rear light with built-in brake light and license

plate light

• Side reﬂectors

• A unique VIN number per bicycle

• Adjustable license plate holder

* These additional parts are all part of the EU Type Approval. It is not allowed to remove or exchange them for other

(non-certiﬁed) equipment. This also applies to the fork, tires, brakes, kickstand, motor, battery pack and display.

3.4.2 Additional parts on 45 km/h EU-models – photos

Front light Supernova M99 Pro High beam switch Rear light, including brake

light and license plate light

License plate holder Lever blades with ball-end

(including brake light switch)

Mirror

(position: above handlebar)

Side reﬂectors A unique VIN number per SC-frame

3.5 Bosch eBike Assist system

All bicycles are equipped with the Bosch ‘Performance Line’ assist system. The exact conﬁguration of the kit

depends on the region of sale. This also determines the speciﬁc ﬁrmware and thus the maximum allowed assist

speed and also speed indication (km/h or mph). Depending on the conﬁguration and region, the Bosch drive unit

can assist up to 20 mph, 25 km/h, 28 mph or 45 km/h.

Refer to chapter 1 for all conﬁgurations of the Trek and Diamant models.

The drive unit is built into the middle of the specially designed frame. The frame has a semi integrated battery

pack and battery rail. The battery can be charged on the bicycle or can be taken from the bicycle to be charged

elsewhere.

3.5.1 Bosch eBike Assist system - overview

Bosch Part Description 25 km/h (Bosch P/N:) 45 km/h - 28 mph (Bosch P/N:)

Drive unit Performance Line 0 275 007 037 (CX) 0275.007.041 (Speed, 45 km/h -28 mph)

Display Purion 1270.020.917 1270.020.917 (km/h or mph on display)

Battery pack Down tube, 500 Wh 0275.007.530 0275.007.530 (EU)

0275.007.533/534 (US)

Charger Standard 4A 0275.007.907 0275.007.907

Bosch eBike Assist System parts

3.5.2 Bosch eBike Assist system – photos

Performance Line drive unit Purion display Integrated down-tube battery

Charge plug Standard charger

3.6 Drive train

The Super Commuter+ and Diamant Zouma+ bicycles are available either with IGH or 11 speed rear derailleur gear

systems. Consequently, the shifter on the handle bar is a IGH shifter or an rear derailleur shifter. From the IGH

shifter, two operating cables run through the frame to the hub, the rear derailleur shifter has one operating cable

routed to the rear derailleur.

3.7 Brake system

3.7.1 Brake system – overview

Model Brake system

Maximum

speed Remarks Region

Diamant Zouma+ Shimano M615 hydraulic

brake system

25 km/h - Germany, Austria,

Switzerland

Zouma Elite+ Magura MT4/MT5

hydraulic brake system

25 km/h - Germany, Austria,

Switzerland

Zouma+ S

Zouma Elite+ S

Magura MT5e hydraulic

brake system

45 km/h EU-Type Approval,

eBall brake levers

with brake switch

Germany, Austria,

Switzerland

Trek Super Commuter+ 8 Shimano M615 hydraulic

brake system

25 km/h - EU

Super Commuter+ 9 Magura MT4/MT5

hydraulic brake system

25 km/h - EU

Super Commuter+ 8S Shimano M615 hydraulic

brake system

28 mph - US/Canada

Super Commuter+ 8S

Super Commuter+ 9S

Magura MT5e hydraulic

brake system

45 km/h EU-Type Approval,

eBall brake levers

with brake switch

3.7.2 Brake system – details

All bicycles are equipped with a hydraulic brake system and have a 180mm brake disc on front and rear hub. The

EU-bicycles with Type Approval have built-in electric brake switches at both left and right hand brake levers that

activate the brake light.

3.8 Fenders

3.8.1 Front fender attachment

The front fender is directly mounted to the fork. On the top, the fender is mounted to the fork crown, with a thin

spacer between fender and fork crown. The other side of the fender is secured to the fork with a specially designed

fender stay. The front fender has a fender end piece at both ends.

Front fender and fender end piece (at both ends)

3.8.2 Rear fender attachment

The rear fender is directly mounted to the frame at the seat stay bridge and at the chain stay bridge (near motor

mount), with a spacer between fender and frame. At the rear it is connected to the dropouts by the rear rack. The

default spacers are 10mm thick at the motor mount and 5mm thick at the seat stay bridge (with the drop-outs in

the middle position). The spacer applied at the lower position may vary in thickness (or even be left out), as the

fender will move with the adjustment of the dropouts. Consequently, depending on the position of the drop-outs,

the distance between frame and fender can change as well. The rear fender is an integrated part of the rear rack

mounting, it acts as a rack stay. The rear fender has a fender end piece at the rear and has a channel for the electric

wiring to the rear light(s).

Note.

Rear fenders are drilled size-speciﬁc; the location of the holes varies per frame size.

The rear fender is mounted to the rack and the frame Fender end piece

The lower spacer may vary in thickness (0mm to 10mm) The top spacer (5mm)

3.9 Rear rack

3.9.1 Rack – design and application

The rear rack is designed to carry a pannier on both sides. The rack has a stop at each side to prevent the panniers

sliding back and forth.

The rack is designed to support the fender – it is an integrated part, together with the drop-outs, of the rear part of

the bicycle.

The rack as an integrated part of the rear end Slide stoppers

The rear fender end piece

3.9.2 Rack – maximum allowed load

The maximum allowed load on the rack is 7,5kg / 16,5lb per side; in total 15kg / 33lb.

3.10 Cable routing

3.10.1 Routing of the front brake cable at the fork

At the fork, a brake cable is led to the front brake caliper. It is secured to the fork with one (or two; depending on

the bicycles’ conﬁguration) fasteners to prevent damage to the brake cable and paint of the fork.

3.10.2 Routing of the rear brake and shifter cables

All cables to the back of the bicycle run through the frame. On each side of the down tube, the brake, shifter and

electrical cables enter the frame via an opening in the frame. From there, the cables run via the battery bay to the

back of the frame.

In the battery bay, the cables are secured to both sides of the battery rail spacers with help of tie-wraps.

The brake cable is led through the left hand chain stay to the rear brake caliper.

The shifter cable(s) run along the drive unit and chain stay to the derailleur or IGH. These cables are ﬁrmly secured

to the drive unit and chain stay with specially designed clips.

There are two types of clips available; one to secure the single cable of a derailleur drive system, the other to secure

the twin cables of the IGH.

3.10.3 Routing of electrical wiring to the front of the bicycle

The electric wiring to the front of the bicycle consists of wiring to power the front light and to the brake switches

(if applicable, depending on conﬁguration). The wires enter the frame via an opening in the frame and run via the

battery bay to the drive unit, along the cables of rear brake and shifter.

All cables running through the battery bay are secured to the battery rail spacers with tie-wraps, on both sides. The

electrical connections at the drive unit are protected by a specially designed cover that ﬁts between drive unit and

frame.

3.10.4 Routing of electrical wiring to the rear of the bicycle

The electric wiring to the rear of the bicycle consists of wiring to the rear light and, if applicable, the brake light and

license plate lighting. Also the cable from the speed sensor is part of the rear wiring.

The wire for the lighting is led through the rear fender. The fender has a built-in channel to hide and protect the

wiring. Four clips secure the wire in the channel (ensure to ﬁt the ﬂat side of the clip pointing to the wiring cable).

At the front end, the wiring enters the motor cover, and is routed to the electrical connection at the drive unit.

The speed sensor cable runs through the non-drive side stay, via an opening in the stay, to the speed sensor. The

opening is covered with a specially designed frame plug. The connector of the speed sensor is connected to the

drive unit.

3.10.5 Cable routing – photos

Front frame entry (both sides) Rear brake, shifter and electrical cables

through the battery bay

Cable(s) at drive unit Top: Cable at chain stay

(derailleur)

Bottom:

Cables at chain stay (IGH)

Front brake cable mounted at the fork Rear light cable, secured with a clip,

in the fender guide

Rear light cable routed to drive unit

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Trek Diamant Zouma+ S Service Information

Brand: Trek

Model: Diamant Zouma+ S

Type: Service Information

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Trek Diamant Zouma+ S Service Information

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