Bosch eBike troubleshooting: smart system and earlier Bosch systems

Many bike brands build their e-bikes around a Bosch drive, and this page is for riders of any of them. It covers the Bosch smart system, which uses the eBike Flow app, and earlier Bosch systems that riders often call Gen 2 to Gen 4, including Bosch eBike system 2 with Purion, Intuvia, Kiox and Nyon displays. See also our systems overview.

Before you start

• Work out which system you have. Smart system bikes use the eBike Flow app with parts like the System Controller, LED Remote or Kiox 300. Bosch eBike system 2 uses Kiox, Nyon or Intuvia displays with the eBike Connect app (Bosch eBike owner's guide).
• Get the quick start guide for your display from Bosch's downloads page. Full manuals live in the manuals section of the Bosch eBike Help Center.
• Switch the system off and remove the battery before you look at connections, the speed sensor or clean anything.

Common problems and what to check

Won't turn on

• Charge the battery and check it is seated and locked in its mount.
• On Bosch eBike system 2, motor support is switched off when the display is removed, so make sure it is clipped in. On the smart system, the drive will not work without the correct digital or mechanical key (owner's guide).
• If the display stays blank, Bosch's Purion instructions say to restart the system by switching it off and on again.
• More steps: e-bike won't turn on and display blank or flickering.

Won't charge or range has dropped

• Use a compatible charger, ideally the original Bosch one. Let the battery cool after a ride and charge it somewhere dry at 0 to 40 °C (32 to 104 °F) (Bosch battery FAQ).
• Bosch suggests occasionally cleaning the battery's plug poles and lightly greasing them with technical petroleum jelly.
• A cold battery gives less power. Warm it indoors to room temperature before you ride.
• Range varies with assist level, terrain, rider weight and tire pressure. Bosch quotes under 30 miles to about 100 miles on a charge.
• A Bosch dealer can test remaining capacity with Bosch's CapacityTester (dealer service).
• See battery won't charge, battery drains fast and e-bike battery care.

Assist cuts out or feels weak

• Assist ends at 20 mph or 28 mph depending on the drive unit, so a fade at that speed is normal (owner's guide).
• Check the spoke magnet sits where it should by the speed sensor (code 504).
• A temperature code such as 540 means the bike is too hot or cold. Let it cool or warm up.
• If the system detects tuning, it goes into emergency mode and stops support. That needs a dealer.
• More steps: motor cuts out and no pedal assist.

Software and app problems

• Smart system: open the eBike Flow app, connect the bike and check Settings, then Your eBike, for updates. They install over Bluetooth (Bosch software updates).
• Bosch eBike system 2: Nyon checks for updates itself over Wi-Fi. For Purion, Intuvia and Kiox, arrange updates with your dealer.

After washing, and routine checks

• Remove the battery and display before cleaning, and never use a steam jet or pressure washer. Afterwards, check the drive works and the buttons respond. See e-bike got wet.
• Check brakes, lights, bolts and tire pressure regularly. Bosch suggests a first dealer inspection about four weeks or 186 miles after purchase. See brakes, flat tire and noises.

Error codes

On the smart system, look codes up in the Bosch eBike Help Center or ask your dealer. The codes below come from Bosch's own Purion instructions for Bosch eBike system 2 (Bosch Purion instructions, hosted by KTM). Codes differ by display and model. For many, Bosch's first step is a restart, then a dealer if the code returns.

• 410 or 418: buttons disabled. Check for a stuck button.
• 414, 422, 423, 424: a connection problem between parts. Have the connections checked.
• 430: the display's internal battery is flat. Charge the display.
• 503: speed sensor fault. Restart the system.
• 504: speed signal distortion. Check the spoke magnet position.
• 530: battery fault. Remove and refit the battery.
• 540 or 605: temperature outside the allowed range.
• 550: an impermissible load was detected. Remove the load.
• 620: charger fault. Replace the charger.
• 656: software version error. A dealer needs to update it.
• 7xx: a third-party part. Follow that part maker's manual.
• 8xx: ABS related. Most need a Bosch dealer.

More general advice is on our error codes page.

Videos

Official help

• Bosch downloads: quick start guides and warranty.
• Battery safety and the battery guide: charging and storage.
• Bosch dealer service: what dealers do and a dealer finder.

When to get a pro

• Any connection or wiring code, or a code that keeps coming back after a restart.
• Updates on Bosch eBike system 2. Dealers use the Bosch DiagnosticTool to read errors, update and give a service report.
• Emergency mode after tuning is detected, and any ABS code.
• A damaged or overheated battery, or one that will not charge with a known good charger.

Sources

• Bosch's downloads page, bosch-ebike.com
• Bosch eBike owner's guide, bosch-ebike.com
• Bosch battery FAQ, bosch-ebike.com
• Battery safety, bosch-ebike.com
• battery guide, bosch-ebike.com
• Bosch software updates, bosch-ebike.com
• dealer service, bosch-ebike.com
• Bosch Purion instructions, hosted by KTM, ktm-bikes.at
• bosch-ebike.com
• Battery Handling, youtube.com
• Battery Safety, youtube.com

Stuck after these checks? Find a shop near you.