How Bosch E-Bike Motors Are Serviced And Repaired

Bosch e-bike motors, like most electric mountain bike motors are very reliable pieces of kit, although as with any mechanism, can wear out. In this video Jones visits Steve Kitchin who demonstrates what the Bosch Service Repair kit can do to get your e-bike motor working again.
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Don’t forget that the best thing to do in the case of motor or battery failures is to take your bike to an e-bike specialist bike shop. If your motor is still within the warranty period then return it to the manufacturer for a replacement, or a qualified specialist will follow these steps with the Bosch Service Repair Kit to make your motor like new again.
The service repair kit is not available for public purchase. Installation and servicing should always be carried out by a qualified specialist.
Thank you to Steve Kitchin:
www.bikekitch.com
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[@embn]

What maintenance would you like to see from us next? ⚡️

[@paulnield6978]

Hi Guys, where can you get the Service Kit from? There are already guys on the web offering a full Bosch motor rebuild with all bearings replaced. Perhaps you could show a complete rebuild? Paul

[@robertwilson4701]

Get yourselves a variety of seat droppers and do a similar class for servicing them.

[@grantjohnson94]

2016/17 Turbo levo brose motor please.

[@bigdirk1984]

@@grantjohnson94 Im from South-Africa and Knipe racing rebuilt my levo motor's BB. Replaced with much better bearings. Louis the owner of Knipe racing has also trouble shooted quite a few things on my levo also so he is getting to know them. On my facebook profile there are few pics of the stripped motor etc.

[@uknorthie]

Specialized levo 2018 please

[@protarget1]

My praise to Bosch. My bike is a 2016 Scott E-Spark 710 with the Bosch performance line CX. I bought in May 2016. In October 2018 the crank bearings stared to have play in them. The motor only has 2250 miles. Took it to the dealer I bought it from and they did a complete motor test ect. They contacted Bosch because of the low mileage. They said I could still use the bike till sorted. 6 days later I was told that Bosch are going to replace motor.4 days later new motor arrive at shop replaced next day with 2yrs warrantee. Well done Bosch :-)

[@mrswinkyuk]

Well, apart from the distracted mechanic, intrusive host and pissed camera man, it was a good video.

[@taxisax6683]

The interviewer needs to stop interrupting the Bosch Expert. I want hear the Bosch Expert. and stop saying BOOM!

[@nickd6056]

Anyone else feel on edge watching this video?? Stressed me out for some reason. I think its Steve touching stuff all through it with the mechanic trying to tell him not to. Also he wasn't really listening, needed a wee ,or was late for something. 🙃

[@oooyugi]

Nick D You need to go see a doc if this upsets you.

[@roncollins9222]

James Parker The Techy needs a 1 m. Steel rule...

[@scottweston8477]

Yes agree he was like an excited kid at Christmas.

[@MrBonanist]

Idd , like watching Ellen 💁‍♂️

[@kyyla1234]

@@MusicMaster961 Dude its a bunch of cheapo plastic cogs, not "delicate stuff"

[@edgarsnezinu1439]

One little tip.... When using torque wrench you should hold it by the handle and grip must be on the end of torque wrench holding close to wrench head wrong torque is used

[@TW0T0M]

I'm sorry but the guy in a black coat is not a good communicator. Step off and let the expert work!

[@twowheelsoneleg5672]

Be great to see a whole series covering the other main motors

[@Ukmongoose3]

This is amazing. I was told by local dealer that spare parts were no longer available for this motor. I didnt believe them of course, so this is pure gold. Do your own research!!

[@Nomads_Rowing]

Interesting video c/o Bikekitch but Steve, you were as useful in the workshop as a chocolate fire guard!! More videos about ebike maintenance always appreciated especially stuff we can do ourselves in the form of preventative maintenance 😎

[@superspecky4eyes]

Steve straight in there with the WD40 plug :P

[@TonyButterworthPhoto]

So glad I watched this video! My Bosch CX motor has suddenly started making a clicking noise and I just saw lots of ££££££££ signs! But was reassured when you said that the motor is covered by warranty up to two years! I’ve only had my bike (Cube Reaction SL 500) for 12 months so I’m going to take it back to where I bought it (JE James, Rotherham) and hopefully they’ll sort it out. Thanks!

[@PaulRotheram]

I Wish you'd of left the service engineer to do it to avoid all the faffing around. Im pretty sure he could of done a good job on showing us the parts etc.

[@mwwssjdh]

I’ve got a 3 year old cx performance line up to 850 miles now; apart from needing tightening up to stop some clunking noises doing great. Battery still doing well, no noticeable drop in range.

[@johnnunn8688]

I’m on almost 5,000 miles in 2 years, without any noticeable performance drop, noise or battery range.

[@re-eo3yu]

Steve …. He said don’t touch!! Bloody naughty kids in the workshop! Lol

[@jamesandrews29]

Great video! Thanks guys.

[@JogBird]

he contaminated the part of the shaft he repeatedly said not to contaminate

[@ed0078]

Agree, the service technician stated it’s a press fit. He accidentally touched it with grease on his gloves making it slippery - oops! But in his defense he seems to be a perfectionist and doesn’t make this mistake as a norm

[@stephenbrown5844]

Excellent guys. Much learnt 👍😁

[@roadrunner3505]

Two Steves.....Good work opening up the "Black Box" we rely on and I'm sure this was a first view inside for many. As I review the comments I wonder why so many viewers have such animosity? All this Tech , of any brand, is very complicated and we should thank those who take the time to help us understand it. Consider showing a full bearing replacement in a future Vid. Cheers from NM , USA. (ps...just received my new Powerfly 5 FS and learning every day)

[@J0nny61]

Very informative, thank you

[@alasdairhill5166]

Excellent video Steve ,I've wondered how easy it would be to maintain the motor since I've had my Bosch haibike

[@agoogleuser8492]

Fantastic video from a great source.

[@alexandervonbraun]

Bosch did a good job with this, they have also upgraded the bearings in the kit over the first batch of motors. However, what isn't mentioned, but probably spotted by anyone watching, they only replaced one side of the motor bearings, the non drive side can't be replaced by anyone other than bosch, so if that side is worn you need a whole new motor. The reason for this is the cadence sensor is on that side and shouldn't be messed with by anyone other than bosch.

[@mikldude9376]

Good to know Alex , i wondee what the expected service life is of that particular bearing in normal conditions ?

[@alexandervonbraun]

@@mikldude9376 unfortunately there are too many variables, but to speak from experience; I have had my bosch performance bike for one year now, used everyday and completed nearly 5k in miles. This is all commuting in London using sport/touring mode mainly. And the bearings are absolutely fine. I'm more than certain I won't be replacing my bearings anytime soon. These motors (and battery) are really reliable compared to the other brands I've encountered. Hope that helps.

[@jasonmvosper3758]

Torque sensor

[@Steve_MFr]

Here is that bearing being replaced. And the torque sensor (not cadence) being removed. Bearing removal starts at 8:20 .

[@dragosvestemean4229]

that s not true, u can find all the bearings for the engine aftermarket and use a press, is not rocket sience, they just makeing to look like this, in reality is a simple engine with some bearings, the rest is just marketing.

[@Rambleon444]

So interesting! Thank you! ~One Grateful dude

[@FancyaBevMate]

Full strip down would be great guys with all the bearings and motor replacement. Cheers

[@user-bd1nf7fl7l]

thanks for interesting subject!!!

[@nigem8111]

I had the 45km 2015 motor the larger nylon cog disintegrated after 14000km I could not get it repaired anywhere in the uk at the time had to buy a new motor from Germany 700€ at the time glad to see there’s a repair kit

[@squirerides8371]

Firstly, this is great news and a really useful vid. I don't think anyone on the forums I hang out on knew Bosch offers a refresh kit. Secondly, why oh why oh why didn't Steve mention the one bit of maintenance you can and should perform regularly on a Bosch CX motor? Bosch document it but so few people know about it: Removing the external seal around the drive side shaft, cleaning and packing with fresh grease. Bosch CX motor seals are a long way from being water proof, and this is the one thing you can do to reduce moisture getting to that drive side bearing in the first place....

[@ep82GTT]

SquireRides what seal is that exacly? You have some online info showing that in detail?

[@simonmiller981]

Good Video Bikekitchin, but why didn't you put grease on the shafts when reassembling?

[@mikec3405]

When an OCD mechanic meets a messy interviewer...

[@Teamcrapsheep]

This video is great if you are a tinkerer like me, more like this please guys.

[@oquefizhoje]

You advise not to touch the shaft and you do not only did touch it but you leave greasy on that also... Your are a Bosch technician, imagine if you weren't. Hugs.

[@5492sparky]

A great watch!

[@OKFrax-ys2op]

Bosch motors rock! Thanks guys!

[@nicholasjones5970]

I would of asked Steve to leave whilst he does the video. I wanted to smack him so bad

[@catherinecedolin3683]

Great video , Are we going to see the same on a steps motor 👌

[@EBikeDarmstadt]

Thanks for this cool Video 👍😎👍

[@Marcos-S316]

Nice Info

[@CrotZari]

A very interesting video and timely too. I myself would love to see a service done on a Yamaha PW motor and I´d love to know if there is a servicekit with new bearings for those as well. I commute on my MTB Hardtail from Haibike and have for the last two years so I expect the warranty to be just about over for me. When I ride to work and it is snowing my motor, or my motorbearings, begin to squeak and I only ever hear that during really cold days, and often with snow. I just looked at my tripmeter and I have ridden 9829 km in the last two years so a service on the motor is probably what the doctor´s ordered :) Keep up the good work.

[@JohnRushworth]

Very handy vid.

[@manuelquevedo6391]

My son loves his bike.

[@hannalarsson8213]

and the bearing on the non drive site?

[@dan123collins]

My exact thoughts, literally half a job with Bosch’s “kit”, I would be very disappointed if this was my motor that got semi serviced. The only plus point was the kit was fairly okay price wise - does seam wasteful binning the entire cover through.

[@MrINKOMPATIBEL]

There is another kit with all the other bearings inside the housing. Its around 200 and you need special tools to change the bearings. google for "motor revisions kit"

[@gnatgnutz7139]

Would this kit fix creaking in the crank noise?

[@danielmerino3983]

Great video! I have an Orbea Katu 2019 with Bosch Acive Line motor, can I change it for a Performance Cx? Where can I find one to buy? Thanks a lot

[@SmileyBoy84]

Don't touch the shaft..don't touch it...then he touches it😂

[@fosterechalimbana2160]

doing a good job & like this

[@robertwilson4701]

I think the concern with shaft contamination is moisture /sweat from your skin, as well as dust / dirt particle transfer which can cause surface corrosion or resistance when one part rotates or slides inside of the other (tight tolerances), exactly the same as auto boxes and diesel injectors in the automotive industry.

[@JohnRushworth]

Robert Wilson I agree. Also I suspect to keep what I think is the trapped roller type clutch/freewheel free from contamination kzbin.info/www/bejne/h5u1aJefotWGgKM

[@kevinargust3694]

Very surprised the locating pin was not greased prior to cog being located

[@scottweston8477]

Yes agree I did wonder about that.

[@benlloyd7938]

You don't want that pin to rotate in the housing, it needs to be semi fixed, it carries a bearing so it has to hold the inner race

[@Rinty145]

As well as noise, would there be play in the shaft when the bearings are worn?

[@fastlanediaries6593]

I’ve just done this very service on my Haibike Nduro...Performance line CX. Bearings were worn and noisy. It’s transformed the bike immensely. A very worthwhile service point and this is THE BEST GUIDE for how to do this on these engines. I would also recommend the dust cover part as an addition to reduce water and muck ingress on the other side 👍👍

[@ep82GTT]

FAST LANE DIARIES Which part is this exactly?

[@mtbsieppo]

It's great that you can service bosch motors. This should be an industry standard really instead of replacing 1000 dollar motor when a bearing goes bad

[@Samuelx123x]

is there a difference between the 65 Nm, 75 Nm and 85Nm versions?? Would the BDU2xx drive unit work on all of them??

[@johnashford5373]

Great video,lm thinking of replacing my active line motor with the active line plus can you tell me if it will slot in to the same mounting and if the electric plugs/clips also fit the same? Without altering anything. Thanks

[@SimonBauer7]

what model year have you got? if you have the older active line that is egg shaped the active line plus wont fit in this case i would suggest to get a performance line non cx from the same year more power + the motor is black instead of grey

[@ilario3752]

Please the same Video with the Yamaha PW-X Drive

[@benwahhhh]

hey, what do you think about the MudStop thing to prevent mud/water getting inside the motor ? is it worst buying this?

[@errolkim1334]

I subscribed the minute I saw this. I bought a Cube SUV 27.5 with the Bosch Performance Line Motor and the E-Harmony Nuvinci Drive. It stopped working in 2016 and hasn't been fixed since. LeisureLake cycles, the people I bought it from, never helped one iota.

[@jonfoxx9745]

Are there any places who can test a bosch active line plus, as I dont have a battery etc to test. Thanks

[@Vidas666]

Hello, wander to ask you if you tune bosch motor that you can reach 45-55 km/t is it possible to damage it. I can't find the highlights on this approach from profesional eye, thx

[@vladthebikeguy4763]

What about the rust spots on the shaft ?

[@ed0078]

Vlad Biciclistul wont hurt anything

[@spiral99able]

that's what she said to gramps.

[@TheZemun]

@Electric Mountain Bike Network Hello, I just saw your video and I have a question , if you can help me. Recently I received an Flyer E-Bike F Series (made 2000-2003) and I wonder if you can help me with repair . It doesn't have tork but battery is perfect . The bike have mid hub motor that I can't find anywhere on internet . Regards.

[@nickwatkins5227]

For something so straight forward I felt nervous 😥

[@kurtXhecticXpl]

Wow, that's a good news! I just called the Shimano and realized they don't provide parts what so ever! After 2y in any case you have to buy a new motor! Just a horrible policy. From now on I'm looking for a ebike with bosh motor on board.

[@flashpoint8909]

I think i need to have a word with my bike retailer, i had my motor replaced after three months because it was too noisy at the first service, same motor as you have just worked on when i asked if the guarantee was now to run from the new motor they said no|

[@garethbarrow4694]

Steve , why are you so inpatient in this video, butting in and touching things that he said don't touch 😳

[@gregchristie2763]

EMBN steve was just trying to make the vid more interesting which he did as usual imo...what would be useful Steve as u asked... more vids would be useful.. is a full strip down of each generation of bosch motor..how to diognose faults..an explanation of each component..what it does..how it works..and how to source spare parts and fit them..maybe thats a tall order..but many of us have bosch motors that are out of warranty 😕

[@jimmiewingstedt5838]

Sooo where can i get the kit from? :)

[@OldNorthern_eMTBer]

Good video 👍 but I'm intrigued as to why you shouldn't touch that shaft? (Ooo'err Matron!!)

[@tomasr64]

My gears finally slipped out from a 2017 raliegh fat tire model. Hope I can find the kit?

[@PhillipYewTree]

My Haibike enduro Mk1 has on two occasions lost drive. Pedals just spin freely. Twice repaired, but I’ve lost confidence in using it. Would this kit (fitted by the Haibike mechanic) solve my problem ?

[@Cuzzazbuzz]

Why do the motors have slack on the driveshaft that means the drive sprocket rattles when the chain bounces around? It’s the only sound on a new bike...

[@IamCutePanda]

I am going to retrofit additional battery on RandM myself , I checked it is possible, it is easy to do from view of the point of the mechanical part...but what should be done with firmware?

[@ipetani]

After how many kilometers should I make this kind of service? Or should I just wait for something go wrong with my motor?

[@davidcart28]

What about the drive bearing on the other side

[@Teodor83]

Which e-mtb to buy specialized levo comp carbon 2018 (ex demo) or new canyon spectral:on 6.0 2018 or 2019? Mainly use it in trail riding.

[@grahamsmith9788]

the Levo 2017 & 2018 frame geometry isn't great - reach is far too short (rectified to some degree in 2019) and I'd say the Spectral is a better bike to ride (if you don't mind that the Shimano motor is much noisier than the Brose), but, there is a lot to be said for buying from a bike shop rather than a direct seller, take a look at www.trustpilot.com/review/www.canyon.com

[@quickcat08]

Hi. I had an active line plus motor fail. Sent it to service agent, got returned, same problem. Fault 0x500332 Internal Drive Unit software error ⇒ no motor support came up. Bosch said it was probably due to water getting in and rejected the warranty (2 1/2 years old) I pulled it apart and found the needle clutch and large main bearing rusted and stuffed due to no bearing protection washer. Cleaned, replaced bearings but still coming up with fault. Bearing kits are not available from Bosch in NZ and they are not happy if you open them up to do the job even if they have rejected a warranty so they refused to help clear the codes or offer any help other than to buy a new motor. How do you get on with getting assistance from Bosch with regards to older motors outside warranty and software issues?

[@steveg4iwr]

It's a pity Steve couldn't have gone to make a coffee or found another job. He was a major pain on this video if I had been the other guy I would have nailed his hands down and gagged him. Apart from that useful to reinforce the two year guarantee.

[@michellemarshall6383]

Do the Bosch motors still have a 2 year rolling warranty from new. My husband had a new motor fitted under guarantee 15 months ago, the motor has failed & Bosch have said there is no guarantee so will not replace, the motor has not been tampered with or opened at any time.

[@andresmartinez1237]

What about the raising complaints worldwide about the Bosch Performance CX? Specifically for loud noise, similar to a coffee grinder..... Apparently the motor bearings get dust... There are more and more customers complaining about this

[@johnnunn8688]

Seriously? That is a lesson in how NOT to use a torque wrench. It has a handle, for a reason. You MUST ALWAYS hold it by the handle!

[@smigielko]

Any chance for a similar video for Specialized? I was unlucky enough to fall in between end of warranty for 2018 bikes and 4 year warranty for 2019-2020. Have to pay £600 of the usual £885 replacement cost (£765 Brose 1.3 motor, £120 labour).

[@rogerwettstein287]

I am assuming, if I do that myself, there is no 2y warranty =) How about diagnostics? Is there a way to get my hands on that software, so I can do that myself?

[@dankhalifa6937]

Hello whats the problem can be when i spin pedals the chain is not moving or barley moving when it got no resistance

[@kayakmadfishing]

How do I get one of these..there is no bicycle shop in ireland that service these motors.

[@19bootsy68]

After 12,757 miles I need this done.

[@leehopkins6983]

Will this cure a error 500 code 🤔 my motor throws up the 500 only when I stop peddling/ or rolling, I then have to turn it off them on again and it works however once I stop peddling again the same 500 code comes up ?? Is this a bearing issue 🤔??

[@fredvallenet]

Is a kit available for an Active Line motor?

[@kingsknightuk]

there is

[@baaffiliate3594]

Thats pretty cool that they extend the warranty another 2 years after the first one! My question is... What about that one! Can that get replaced again under its warranty? Then again? Then again? That would be great to get a new motor every 2 years! providing it breaks down every two years lol!

[@tehsimo]

VERY surprised to see plastic components in the drive train

[@russ18uk]

Noise reasons. Don't wear that quickly either.

[@tehsimo]

@@russ18uk Probably more to protect the motor than for noise

[@russ18uk]

Partly true. It is a sacrificial part, but the noise is a lot lower with nylon gears.

[@sakariputtonen2683]

weight, cost two main reasons, those gears are also used in automotive industry so it's also cheap as soap. @@russ18uk

[@TheOffroader7458]

@@sakariputtonen2683 nothing cheap about ebike motors .

[@samirhafsa9818]

Hi how to order this kit plc

[@martinlewis1015]

If you were to list all the motors into order of most reliable, torque,power etc and your choice of which you prefer?

[@OnlyDans848]

Has anyone has fixed the standard 'free wheeling/decending' rattle with this service?

[@wasuppa]

I have a couple of Haibikes, both with the Yamaha motors. One is a 2017 sduro 6.5 nduro, and the other is a 2016 cross sl. Both are still within the first year of warranty. Both, especially the 6.5 (which has almost a thousand miles on it) are noisy. They both whine pretty loudly when the motor is providing power under a load (going uphill). If the power assist is small, the whine isn't too bad. But when on a steeper grade, the whine gets louder. Is this typical? Or could this be a defect? Do all Yamaha motors do this? I ride with other e-bike brand riders, and they are much quieter...especially the Brose motors, which have belt drives. I want to know if I can get this whine to go away....very annoying....the critters hear you coming from a long distance. Any ideas?

[@zurri6513]

It has a set of straight cut gears inside, it's normal for them to whine.

[@seymourtompkins]

The Haibikes/Yamahas I've ridden were the Enduro 10.0 and 8.something- MY 2017. They were both pretty quiet compared to the annoying Bosch whine (but nowhere as quiet as my new Brose)

[@Threadexpress]

Please do the same video for PW Yamaha!

[@fatihemre5019]

Hello, my bike has active line plus motor. I got error code 500. How can you help me? Bike is 3 year old and 2500km.

[@MrKiselinov]

Please tell me were I can find that repair kit to buy it, can you give me link or such :)

[@richardpreece4974]

Bosch have updated their warranty and dont do a rollover warranty, had one replacement in july 21 its done 290miles and its stopped, they offered a 50% discount as a good will gesture

[@70darylb]

i own a focus bold 2 hardtail and my motor has broke 4 times had 2 new motors and had 2 repairs 2 motors have broken around 400miles :L

[@kayakmadfishing]

Can I send my motor to you too get it fixed.

[@p2e]

I’m late to the party watching this vid months after first release, but hopefully you guys at EMBN still check these comments- would love to find out if Bosch could eventually(?) offer full newer-gen motor upgrades for owners of older-gen motors. I have what you’d call a 1st-gen Performance CX with tiny sprocket on my 2017 Trek Powerfly, but would love to install the newer motor that works with more standard chainring (large sprocket) setup. On any future segments like this, could you ask Bosch if this upgrade was possible (with/without optional display upgrade option; and even offer latest battery tech upgrades for legacy connectors, ie. for longer range/smaller size)? I’m hoping Bosch have intention to support these products for the long-term, and not abandon its older customers.

[@Cornel1001]

After 18 months of use and 5500 Km I have a strange noise on the left pedal. I have removed the crank just to notice the noise is from inside of motor!

[@timking8617]

Is this still relevant that the motor is still under warranty even if it’s been replaced once already, where the bike is 2 and a half years old, and the motor is only a year and a half old? I’m being told that it’s a cut off 2 years from when the bike was purchased, nothing to do with however many motors you’ve had even if you had a motor a week before the 2 years is up, it won’t then be guaranteed??