Many of you probably know: Replacing worn-out parts on an ebike or changing the standard equipment with products from other manufacturers is subject to certain specifications. Not everything can be combined or extended at will. This is a big issue, especially in bicycle workshops. However, for anyone who likes to tinker at home as well. A guideline from the German “Arbeitsgemeinschaft Bauteiletausch an E-Bikes und Pedelecs” (Working Group for Component Replacement on Ebikes and Pedelecs), for example, summarises what can be done and what is better left undone in this regard. It has now been revised after about five years.
Restrictions with regard to riding safety
Due to the power of the motor, pedelecs are exposed to greater loads than regular bicycles. This is especially true for speed pedelecs, whose power unit supports you up to a maximum speed of 45 km/h. To ensure the greatest possible safety, all parts and components belonging to the bicycle are tested in detail. If they pass the test, they receive a corresponding certificate so that the tested quality can be recognised at any time. In Europe, this is the CE mark. It signals to you: This part meets the requirements of the legislator and may be installed on the pedelec or speed pedelec. Conversely, parts without a valid CE certificate may not be used.
Technological and material advances push the limits of what a bicycle, what its individual parts can do. In order to keep pace with such developments, related recommendations for action must be reviewed at certain intervals and updated if necessary. In the case of the “Working Group on Component Replacement on Ebikes and Pedelecs”, the following German testing institutes and bicycle associations coordinate their efforts: the velotech.de company, Zedler-Institut, the Bundesinnungsverband Zweirad-Handwerk (BIV), TÜV Rheinland, the Verbund Service und Fahrrad (VSF) and the Zweirad-Industrie-Verband (ZIV). After taking into account the current state of the art and the legal regulations, the assembled expertise recommends the following procedure in the context of a repair or replacement of parts:
Recommendations for handling pedelecs
Approval of the vehicle manufacturer / system provider required:
- Motor
- Battery
- Control unit on handlebar
- Charger
- Sensors
- Electronic controls
- Electrical cables
Approval of the vehicle manufacturer required:
- Frame
- Fork
- Brake system
- Brake pads for rim brakes
- Wheel for hub motor
- Rear carrier
Approval of vehicle or parts manufacturer required:
- Tyres
- Brake pads
- Brake cables/brake lines
- Handlebar-stem unit
- Saddle and seat post
- Headlight
- Crank
- Chain / belt
- Wheel without hub motor
- Rim tape
On the pedelec, the chain is one of the parts for which approval is required – either from the bicycle manufacturer or the manufacturer of the chain.
No special approval required:
- Head bearing
- Inner bearing
- Stand
- Front derailleur
- Rear derailleur
- Shift lever / twist shifter
- Shift cables and sleeves
- Chainring / pulley / cassette
- Chain Guard
- Pedals
- Wheel guard
- Rim tape
- Inner tube and valve, each of the same type
- Dynamo
- Battery/rechargeable headlight
- Rear light
- Reflector
- Spoke reflector
- Grips with screw clamp
- Bell
Accessories with special instructions for mounting:
- Child seats
- Trailers
- Additional rear carriers
- Rear view mirrors
- Front baskets
- Panniers and top cases
- Fixed weather protection
- Additional battery/rechargeable headlights
Recommendations for handling speed pedelecs
Valid test certificate (parts approval ABE, EG, ECE) or parts certificate required:
- Brake system
- Brake disc / brake line / brake pad
- Handlebar-stem unit
- Seat post
- Headlight
- Tail light with brake light and number plate light, if applicable
- Reflector
- Rear view mirror
- Horn
- Pedals
Consideration of special conditions:
- Head bearing
- Inner bearing
- Crank
- Chainring / pulley / cassette
- Chain / belt
- Chain guard
- Rear and front derailleur
- Shift lever / twist shifter
- Shift cables and covers
- Tyres
- Inner tube
- Spokes
- Rim tape
- Wheel protectors
- Saddle
- Pedals
- Grips with screw clamp
Inadmissible accessories:
- Additional battery-powered headlights
- Handlebar ends (bar ends)
- Front baskets
- Children’s trailers
- Trailers without the appropriate connection certificate
Components that are missing here in the list for speed pedelecs may only be replaced with original components from the vehicle and/or component manufacturer. As mentioned, this applies to bicycle workshops as well as to you privately. If you want to be on the safe side, take another look at the manufacturer’s documents before starting the actual work.
Basically, you can use the recommendations of the working group as a guide for your own projects. It will also help you understand why, when you ask a workshop for help, the answer is: “No, unfortunately we can’t do that for you.”
Pictures: Shimano; BH Bikes Europe, S.L.