How Bosch E-Bike Motors Are Serviced And Repaired

How Bosch E-Bike Motors Are Serviced And Repaired

– We get a lot of concerns on the channel about buying second-hand e-bikes. At the same time, we get a lot of concerns about the longevity of e-bike motors. Well, today we’re gonna put
all those worries at bay. I’m gonna have a look at
a very inexpensive way how to refresh your Bosch
Performance Line CX motor. Steve, before we begin, let’s
talk about the Bosch warranty on the Performance Line CX. After all, you are a service agent for– – I’m a Bosch service center agent. – All right. So what happens if you have
got one of these motors and you’ve had it for less than two years? – So if you bought a new bike, you cover the bike for two years. So if your motor goes wrong, it’s a complete new motor.
– Wow. – Nothing gets opened up.
– That’s pretty cool. – The motor’s have been out since 2015 so there’s a lot out there,
they get a lot of wear, they’re used hard, and
it’s like a bottom bracket, anything is gonna wear. – So what happens if you
do happen to get a new unit under your warranty, does
your warranty get extended for a further two years? – So yeah, yeah you get
an additional two years. It’s just–
– That’s pretty cool. – Which is a cool thing,
a very good thing. – Yeah, so if you’ve got
any problems in your motor in that two years, then
you can just simply get back to Bosch and they’ll
renew it for you, right? – That’s correct. – If your motor is within the warranty, can you fiddle with it and take it apart? – You can’t touch it. (laughing) That voids the warranty.
– Right. – These little screws here have got rubber coating all over them. If that rubber coating
isn’t on there anymore, that means you’ve been inside it and you have no warranty. So don’t go taking it apart if you’re within your warranty period. Just go back to your Bosch dealer. – Alright, now my eyes been drawn to this little box over here. What have we got over here? – [Steve] Okay, so this
is a service repair kit for motors that are no longer in warranty. – Right. – So it’s a motor, it’s got bearings like your bottom bracket. – It’s gonna have wear and tear, right. – It’s gonna have wear and tear. If you start to feel your motor bearings getting rough and noisy,
noisy’s the main thing. You start to hear a bit of noise. This is the kit you need,
it’s a service repair kit. It changes the main drive bearing. – Right, great, well I think
without any further ado, Steve, let’s get stuck in and fix this
new kit, to this old motor. – So, Steve, the first thing we do is we keep everything clean. And one another thing is —
– Yes, I’ve got that on the checklist. – Ya got that? – I’m gonna be doing the
checklist on this motor. If ya don’t mind.
– Yeah, it’s really important that when we open this unit up, everything is really clean. You see that we’ve got
stainless steel worktops. – Well, it is like a kitchen
as you’ve rightly called it. – So, first thing is, we got to get clean, so I’m gonna put my
gloves on, don the gloves. I bring my cleaning bucket into play. And, I’m gonna put the
motor in the cleaning bucket and I’m gonna take my spray cleaner. This is one of the new range for Muc-Off, which is specific
e-bike range, which is good. It’s actually a dry
cleaner, so you haven’t got to get it wet, so you
haven’t got to worry about that. – I guess you can get cleaner
from any other brands, like WD-40 and everything like that. – Yeah, there’s lots of cleaners. So we give that a wipe over, make sure everything is super clean
when we come to break into it. – There she is!
– Onto the bench. – I’ll clean up after ya.
– Get my bucket away. You can tick me off there
for cleaning the motor. – We’ve done that. – We’ve done the cleaning of the motor. First job is, we remove the circlip. So, circlip pliers. – That’s not a bad pair, is it? Good solid pair of circlip pliers. – Yeah, they’re handy. – I can tick that off then, Steve? – Yeah, tick that off then, thank you. The next thing we do is
– Open her up? – Remember I said about all
the rubber in the seals. – Yeah.
– We gotta get that out. It’s a right pain, so we
have to get our little pick in there and get it out.
– Right. – And luckily, what we did earlier. – Yeah, this is actually
a procedure, isn’t it? – Yeah, it is a procedure, yeah it is. We’ve got a checklist and everything. So, the first thing we do
is we loosen the box off. And it’s all just, we’ve
got six T25 bolts here, that we need to remove. – Those are the ones you
cannot touch, if your motor is still under warranty. – You certainly can’t. So, we got this going and
to speed it up, I’m gonna get my power drill
– Is that a Bosch power drill? – It is a Bosch power drill, yeah. Yeah, look at that. – Fit a lock ring. – Fit a lock ring?
– We’ve got a lock ring. The lock ring is fitted. So, bearing puller. – Bearing puller goes over
the top like hangs on the lock ring and then we wind
it on the crank bolts. Can you see it lifting there?
– Yeah. – Look at that. – I can now check that off I think. – I think you can. We’ve lifted it. And we lift the motor and we’re all out.
– I mean, she’s not too bad inside really. – Well, it’s gonna to be spotless inside they’re so well sealed. So we got seals all around
the edge, the edge of here. – Yeah.
– You can see inside. The first thing we do
is we check to make sure everything is clean. Everything is good and that
shows there’s no contamination. – No signs of corrosion
or anything like that? – No, look at it. It’s like.
– Yeah. – It’s like new.
– Yeah. It’s just making a noise it’s all. – Yeah, it’s making a noise
and as you can see, you’ve got no more crank axle in here. And it runs on a bearing. – I’m I gonna check off, check for signs of damage or corrosion? I think we’re good aren’t we? – We’ve checked and we’re done, yeah. – Ah, right. – Okay, so now we remove
the freewheel sprocket. And this is this unit here. And that just press
fits and that comes out. It’s really important that we don’t touch the shaft, we only touch this, because we’re gonna reuse that. So, for the time being I’m gonna put that on the bench, there. – But is it worth opening up? I’m quite eager to see what’s in the box. Is it a good time now or should we wait? – I think we should. (laughing) I think we should, let’s do it. – Let’s go see what’s
in this Bosch box there. Ah, so there you go, that’s it. There it is Josh. – [Steve In Black] It’s
like Christmas, isn’t it? – [Steve] It is like Christmas. We gotta keep this really clean, so – [Steve In Black] Okay. – Make sure you don’t… – Sorry, I just wanna show you guys there, what we’ve got here. It seems to be lots of parts in there. – [Steve In Black]
Whole kits, o rings, and – [Steve] Special grease. – [Steve In Black] Special grease. Ah, all the replaceable bolts. Ah, that’s pretty good, isn’t it? – [Steve] It’s the whole lot, yeah. – [Steve In Black] Well leave that there. What’s else we gotta do before we get the new part in, then? – So we need to remove the locating pin. It’s a pin that the sprocket (mumbles). – Yeah, I can see the locator pin there. – Okay, and that’s it. – There’s one of them. – Yeah, so pliers.
– Yeah. – [Steve] We’re just gonna lift it out. Give it a bit of a twittle. There she is.
– [Steve In Black] Yeah. – [Steve] Out. – [Steve In Black] And
the rubber seal as well? – [Steve] There’s a little rubber seal. Sits on the little rubber seal. – Is there another o ring in here? – Now the other o ring, is the o ring that sits on the shaft, here.
– [Steve In Black] Yeah. – [Steve] So again with
the pick, we’re gonna pull this out, and get rid of that o ring. – [Steve In Black] Next, I
step, I think we’re done. So we’ve got the lubricating pin. Check. – Done that. Check PCV heat pad is on PCV? – Ah, now, this is the heat pad here. – [Steve] This little thing here. And we’re on. So, we’re covered. We’re ready to go. – So we’re done on the
first part of the process of opening the motor? – Yeah, we’ve done it. – Now we’re onto stage three.
– Okay, now the next thing. Before we put the new one on. We need to give this a quick clean. So, first of all we need
to make sure there’s no dirt around the edge. So, I’m gonna take my one and three cloth, lint-free cloth that was. Spray some cleaner on that. And just work around the
edge, being careful to brush outwards and not
inwards, because anything there, we need to push outside the motor. – [Steve] Okay, so we’ve
got the rubber washer. – [Steve In Black] Yeah. That sits on the rubber sleeve. – [Steve In Black] Yeah.
– [Steve] Yeah. That goes on. And then peel this adhesive backing off. They’ve done a good job,
they’ve made it really simple. And then you locate this into
there, and push it into place. – [Steve In Black] Boom! – [Steve] Done. – (Steve in Black] Boom! Are you gonna put that pin, while you’re at it? – [Steve] The pin,
drops in, and slides on. And we’re done. So, now we need to clean
the bottom bracket shaft. So, just to make sure
everything is nice and clean. Before we put the o ring on. – Steve, can I put the o ring on? – You can, Steve. But before you do that, you
need to grease on the shaft. – You can do that.
– Shall I do that? – Okay, I’ll do that. So we just get my little brush and we’ll just paste it around here, make sure it’s
all in the right place. – [Steve In Black] Good to go right? – [Steve] Good to go. – [Steve In Black] Stick it on there. Gently lift. I can’t get it, it’s just
too much of a fiddle. You do it. – [Steve] So we’ll get
that down and we’ll move it down to the right recess,
which is that one there. – [Steve In Black] Boom! – [Steve] And then we’re in place. – [Steve In Black] Right, I just need to update my tick offs. Clean rubber housing. Clean the BB shaft. O ring, (mumbles) done that. I feel like that moment
has come when we can open the package up. All we’ve got is six bolts left, yeah? – Yeah, they’re the retaining
bolts for the motor. We need those for (mumbles). – Can, I open the packet? – Yeah, let’s open it, yeah. – [Steve In Black]
There ya go, that’s them I’m interested to see what
you get for your money here. Wow, that’s a pretty significant part. – Be careful not to touch
the inside of it, we need to keep it
– I’m gonna put that there. So you be careful when you take this out. So I guess, I guess that comes out and there it is. And that is your new unit. I mean you get quite a
bit for your money, there don’t you really. So, we’re talking. For this kit. How much is it for the kit? – Well, the kit is, 99
pounds, for the kit. That’s good isn’t? It’s gonna totally
refresh your bike, right? – Yeah, you think about
what a bottom bracket costs, in a bike. – Yeah, exactly. – It’s like, it’s good value. (mumbles) – [Steve] Look at the amazing
detail of the bearings? That’s a really complicated bearing. – [Steve In Black] So, can
I just give this to you? I feel like that uh. – [Steve] Yeah, let’s take it. Yeah, let me take it. – Next job. – Next job. We’re gonna grease this
sprocket, ready to go on. So, sprocket, grease. – [Steve In Black] Bosch grease? – [Steve] Bosch grease. Work it around. – [Steve] Quite nice doing that. It feels like icing a cake. Get the brush and just wipe
it all into it’s place. – [Steve In Black] Honestly,
this motor is gonna be so smooth when we put it back together. – We’ve greased this. And we pop it into place. – [Steve] So that sits, the locating pin, that we stuck on with a pad.
– [Steve In Black] Yeah. – [Steve] This sits in
there and presses into that little wheel there. So, it’s just a case of dropping it in. And that is located. That is done. – Guess all is required now
is, to pop the freewheel, uh thingamajig on?
– Yes, remember this is is the bit that we don’t touch. So, we need to give this a clean. Let’s give it a clean. Where’s my cloth, lint-free cloth? – [Steve In Black] Here ya go. – What did you call it? – Lint-free cloth. There’s no lint in this cloth. And so for the first
thing is we’re gonna clean this, but we’re not gonna
touch the shaft, we’re just gonna get the old grease. It’s actually still amazingly clean. But we give it a wipe off
because we have the new grease. So we put new grease on. So, there we are. New grease. Again, work it around. Paint brush there. It’s like being like a dental nurse. Paint brush? – Oh sorry, there ya go. – We’re fully greased up. – Yeah, greased up. Slot her in. Slot her in there or slot her on there? – [Steve] It’s gonna
go onto the shaft here. So we’re gonna drop it in. – [Steve In Black] Engaged? – [Steve] Make sure it’s engaged. Fit it in with a coax. Can you see that? The wheels are in motion. Look at that. We located. – Well, can I go back to my checklist? – Yep. – I neglected it for a minute. Greased all that. Greased that. Greased sprocket. Checked the new cover seal
and see if it’s not damaged. – Check to see if cover
seal is not damaged. – Okay, did you do that? I’ve done that. – [Steve In Black] Check and see if cover seal is all in place. – [Steve] Cover seal all in place? – Yeah. And I think, now too, uh,
put the top on the pie? – We’re ready to go with just the icing. So, we take this, we
check the seal is good. We gonna flip it over, and not gonna touch any of this. Gonna flip it over, and
drop it, into place. I say drop it gently, ease it into place. So, there we are Steve. We’ve dropped it into place. We’ve done it. Okay, so next thing, Steve. Circlip back on. This is important, so circlip, open it up a little bit, drop it into place. And there we are we located it. And that’s it, done. – All that I’m seeing
now Steve, is six bolts. – Six, bolts. – Yeah, we’re gonna put the bolts in. And I’m now gonna remove
my gloves, because I’ve got grease on them. – Means I can help you with this, then? – You can do that. – [Steve In Black] I can see
you eagerly waiting there with the Bosch screwdriver. – [Steve] I am, now this is important. When you do this, you need to make sure that the pressure is right. – [Steve In Black] Exactly. – It’s like doing the car wheel. Let’s alternate sides first? – Exactly. – Don’t go in the clockwise
or anticlockwise motion. There ya go. – So, I got my drill, and
I’m just gonna loosely drive these down. – [Steve] Like the car wheel nuts. Do opposite sides. – [Steve In Black] Boom! – [Steve] So, there now
at least you’re done. So, what we now need to do is get the six newton meters. We need to get our torque wrench. We’ll just give them, and
do it like the car wheel. Do opposite sides. – Alright, Steve, we only got a couple of things left to tick off there. – We’re nearly ticked off, aren’t we? – Fit it back in the bike and it says here, diagnostic. – Diagnostic is great. We plug it into the
laptop and it’ll check on the whole motor. Make sure everything is
working as it should. But, it’s also an opportunity to the upgrade the latest firmware. Two years ago, 2016. Bosch upgraded to the… – The eMTB, – MTB right. eMTB mode. – It used to be called
Sports and then eMTB mode. And that’s the mode that will
work between, flows between – It’s like (mumbles) my car. – Right, it works to how much
power you’re putting down. It gives you that, you pedal
harder, you get more power. So, you’re not gonna (mumbles) – Make sure you get that
eMTB upgrade on your bike. – You’re not gonna hit turbo
when your not expecting. – Okay, one more thing
I was gonna ask you. Now that’s fitted. What’s the warranty
situation with that bike now? With that motor? – So what we’ve done there,
the new drive bearing has now got a two year warranty on it. Which is great, because you’re covered. If it goes wrong within two years. It’s warrantied. – So yeah, that’s great. Depends on where you live and the conditions you live in, and the ground conditions, every motor, in
different part of the whole, is gonna have a different wear age, right? – That’s a really important thing. – Yeah. – Where you’re using it. What you’re getting it. How muddy you’re getting it. How you clean it as well. Don’t go into it with a jet wash. – Yeah. – Try and keep it as
– But I think the important part is like you said,
Steve, is like be proactive, you know, keep an eye on your motor, and give your motor some love. And give it a bath. Steve, thanks so much for
showing us around the fix on this motor and
– Thank you. – And don’t forget to check
out the Bicycle Kitchen. – [Steve] My web address is – Bike kitch?
– Bike kitch. We leave the link at the
bottom of this video. – [Steve] There’s a whole
section of on what we do with this thing. Which you’ll find out on the site. – [Steve In Black] So
let, one final thing. Money-wise, we’re looking
at 99 pounds for the part. – (mumbles) – So, we’re looking at a couple hundred quids to get this done? See there ya go, I hope to
see your comments below. I hope it’s taking away some
of your worries and fears, not only, about buying
second-hand e-bikes, but of the longevity of the
e-bike motors in general. Don’t forget to like, share,
and subscribe to the EMBN. You’ll see some more Bosch
content as in one on gearing, which you’ll find.

85 Replies to “How Bosch E-Bike Motors Are Serviced And Repaired”

  1. I'm still gunna wait for electric knees, and also Steve Kitchin was a sobering presence of calmness through out the refurbish

  2. The presenter ain’t good at his job , wanting to get involved in the repair then backing out , interrupting the mechanic etc , plus crap accent

  3. 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.

  4. 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.

  5. 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.

  6. I noticed you cut the shot where he he should have said how much it cost all in. I bet it's more than just a couple of hundred, more like £300+ with his labour.

  7. 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.

  8. Haha warrenty void if opened?
    That will last 30 seconds when challenged in court!
    When will manufactures realise they cannot do this..
    FTC in the US is very clear on this and same with trading standards in the UK.
    Warrenty void stickers or similar are BS.

  9. 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)

  10. 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 👍👍

  11. The cx with the small sprocket is a failed construction. At first there a reduction sprockets after the motor, and then at the end there is a 2.5 expansion. Makes no sense. Active line plus motor is much better.

  12. Question: I had got a new YAMAHA motor (GIANT E-MTB) inside the warranty time of 2 years. Will the warranty time extend another 2 years like you said with the BOSCH motor?

  13. I'll be using the services of this chap when my CX is out of warranty… can get a full strip down, rebuild with all new bearings, seals, o-rings and circlips for £280(plus postage)……

  14. 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?

  15. 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.

  16. 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. 🙃

  17. What this doesnt mention is that there is an issue with the seal letting in water, which is why Bosch are supplying a complete new case that modifys the seal to cure the leak issue I believe. Would be nice if that was addressed in this video. Oh and for gods sake Steve do shut up.

  18. 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

  19. Having fun is apparently more important than providing useful content. Tall guy is a moron. Wouldn’t let these guys near anything I incompetence.

  20. 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….

  21. 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…

  22. 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 🙂

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

  24. 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 😎

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

  26. that's all fine and dandy BUT what about the other bearing on the other side of the shaft if water has got in it would have definitely affected the other bearing its like a car you do not change a bearing on one side and not the other the only good thing is you get a new 2 year warranty so its just a bad fix Bosh must no that these motors will fail with all this water and dirt they cannot stop getting in there motors and its just not Bosh its all E-Bike motors have the same problem water and dirt do not mix with electric motors

  27. 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.

  28. 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.

  29. Warantee means zipp ! depends on the shop ! they can say its rough treatment or any excuse they can find ! How nice an industry of thieves ! Some are ok , my experience all $ hungry ! In Australia ! shills !

  30. 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!

  31. 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

  32. 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|

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

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

  35. 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 to diognose explanation of each component..what it 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 😕

  36. Please redo without a sidekick and decent multi camera angles. No rubber No Warranty. Remove rubber, replace parts and you have warranty?

  37. @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.

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