bosch mid drive retrofit controller ever done?

luap321

Pedelecer
Aug 30, 2022
39
1
my farther has a cube with bosch mid drive an belt drive nuvinci hub with harmany sync the hub went wrong a few times an had to go back to germany i think for repair under warranty which has now expired my dads is 73 an really liked the bike went out for miles everyday sometimes 3 times a day anyway it developed a fault with the display an he could take it off wipe it put it back turn it on an off an it worked oneday he poped to see my nan didnt turn it off had some sort of problem with it got it working rode 1/2 mile home an it cut out on the way my brother took him an his bike to a bike shop who couldnt do any thing with it an he brought a s/h giant which has now also packed up i think he felt its better than nothing but not as good as the cube ,he now has a carrera subway 2022 s/h 2 months old just under £500 .its ok but ,(he has to peddle fast to get assistance ) the cube was better an he wishis he had his cube working think its been to a few shops an no joy he kept wanting me an him to look at it so went over it with an avo noticed if you move the wire coming out the display base to the remote switch you lost continuity so we shorteded it to do away with the dogiy bit only 2 wires well 1 and a screen round it differnt buttons give differnt ohms reading so shortining the wire was not really a good thing as may affect it it has error code 500 i belive internal motor fault from what i have read bosch dont supply internal parts buy a motor i dont think the sell his motor any more buy a new bike .his harmany sync seemed to stop working an it was just in top an he was happt with that .
so i woundered if any one has fitted somthing like a kt controller and display there is a speed scensor on the wheel 3 large wires from the motor a crank sensor with large black conector an hall sensor or equiverlant on the end of shaft comming out the motor ,i cant work with bosch system an need to conect to computer an all that, but dont see why if its a fault with electrics it carn be run off more freindly version like a kt controler if the crank sensor is u/s then an external one can be used im not sure about hall sensors for motor if needed or how to work out what we have on the circit board or if i could get a signal from something fitted to the rear wheel or with out the large circit board in the gearbox could i drill the plate and araldite them into the front of the motor ?
has anyone heard of any thing like this being done?
his harmany sync could go to cable opperated i think.
sorry about spelling .IMG_20220905_155318.jpgIMG_20220905_155328.jpg
 

Woosh

Trade Member
May 19, 2012
21,568
17,403
Southend on Sea
wooshbikes.co.uk
I don't think you can use a KT controller on your dad's Bosch bike.
It's a locked system, like the phones. You can't turn on the battery without the Bosch LCD and the Bosch controller inside the motor.
The simplest solution is to go see a Bosch dealer.
 
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luap321

Pedelecer
Aug 30, 2022
39
1
I don't think you can use a KT controller on your dad's Bosch bike.
It's a locked system, like the phones. You can't turn on the battery without the Bosch LCD and the Bosch controller inside the motor.
The simplest solution is to go see a Bosch dealer.
i think its been to a few an been conected up the shop has spoken to bosch whilst hooked up an they cant find the fault .
i just spoken to my dad an hes going to take it to a man with a shop who is very good with bosch ebikes the other shop recomended him but due to covid its been on the back burner it would be great if he could have it all as it should be he dose have short arms an deep pockets an i can see it costing £300 for display & base +h sync with out cost of diagnostic an what ever is faulty if they can get the part which from what i have read on the net you cant get bits for
i was thinking bin all bosch electronics just keep the motor and gearbox and see if i can use the pas and the small circit on the end of the motor shaft, if they are faulty use a external universal fitting pas ,if i need hall sensor an if the small board dose not work fit hall sensors in the plate that holds the front bearing , if the battery is locked to the bosch system then i think it could still be done with a new bms or battery just seems to good to be disposable
 
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Woosh

Trade Member
May 19, 2012
21,568
17,403
Southend on Sea
wooshbikes.co.uk
I can see that you have done a fair bit of thinking about this.
Assuming that you re-use only motor and gearbox, how much do you think that this project is going to cost?
 

luap321

Pedelecer
Aug 30, 2022
39
1
£50 controller
£30-80 for display
£6-15 pas
hall sensors 30p each ?
£15-50 bms or battery £180
display with kt lcd4 type he has issues thinks bikes not working cant see assist level didnt know the was another button so not clear enough but i have a lcd8 on way to me for my bike an think i can set up his bike with mine an fit basic led type not sure ,if not it will need to be big an waterproof may be lcd3 if it can be locked so he dont go miles away an start pushing wrong buttons .
battery wise i have a spare battery for his carrera with base an he has a charger for his, i brought a accident damaged frame with battery fitted to it for my bike that i brought with a dud battery mine was 2020 frame was 2021 his bike is 2022 the 21 battery has 2 large wires an 2 small in the mount i would need to find out if this is just for switching battery on an off from display or if it talks to the controller failling that he could borrow the battery from hi giant with a fault in the rear wheel
the advantage of this system is hes not held to ransum every time it goes wrong an is home fixable ,hes bosch system will become un suported by bosch an this would keep it going think my brother brought it s/h for £1700 an its alot of money to say o thats out of date now i know hes had it mybe 4or5 years now maybe longer but i am just resarecting my claud buttler mtb i brought s/h in 98
 

Nealh

Esteemed Pedelecer
Aug 7, 2014
21,702
8,829
62
West Sx RH
Someone has modified a bosh motor to work with KT controller kit, I saw it either on ES or the german forum. They had to do some work with adding halls to the motor so might be worth a search to see.
 
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luap321

Pedelecer
Aug 30, 2022
39
1
Someone has modified a bosh motor to work with KT controller kit, I saw it either on ES or the german forum. They had to do some work with adding halls to the motor so might be worth a search to see.
hi Neal thanks thats great news im not sure who the ES or german forum are, im a bit new to ebikes only got my first one a month ago an not rode it yet wounder if you could pm me the name of the sites
thanks paul
 

Nealh

Esteemed Pedelecer
Aug 7, 2014
21,702
8,829
62
West Sx RH
pedelecforum.de is the german one.
Endless Sphere is the US one, both are much larger then this one and are highly techinical in a lot of the content.
 
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soundwave

Esteemed Pedelecer
May 23, 2015
17,980
6,728

he might have a controller he could sell you or a new motor refurbished one.

 
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luap321

Pedelecer
Aug 30, 2022
39
1

he might have a controller he could sell you or a new motor refurbished one.

thanks its booked in with a man on the 20th who is said to be very good with bosch hopefully he will find a fault an we will know whats needed