mnaeh

***SOLVED (definitely). It was... drumroll... INTUVIA MOUNT*** I'happy to report that I'm part of the #teamnocutoffs While I completely agree that any of the components can be the potential culprit, for me the guilty one was definitely Intuvia mount. It's just that my "testing methodology" was flawed. If you have the opportunity to change and test different components (mount, display, battery, cables…) go for it, but if you don't, I can tell you from my experience and everything I was able to dig out on the web, go with the mount. It's the cheapest solution for the best chance you can get. Having no more mid-ride cut-offs is more awesome than you imagine. Like having a new bike.

***SOLVED (definitely). It was... drumroll... INTUVIA MOUNT*** I'happy to report that I'm part of the #teamnocutoffs While I completely agree that any of the components can be the potential culprit, for me the guilty one was definitely Intuvia mount. It's just that my "testing methodology" was flawed. If you have the opportunity to change and test different components (mount, display, battery, cables…) go for it, but if you don't, I can tell you from my experience and everything I was able to dig out on the web, go with the mount. It's the cheapest solution for the best chance you can get. Having no more mid-ride cut-offs is more awesome than you imagine. Like having a new bike.

***SOLVED... kinda*** https://www.pedelecs.co.uk/forum/threads/bosch-motor-display-cutting-out.32097/post-654362

***SOLVED... kinda*** You can find Bosch 2020 Dealer Manual here. On page 201 there's info regarding new mount for Intuvia (see picture). When a company decides to change the production of a component "to improve contact quality" you can be certain it's simply because the old design didn't work well... for some people This got my hopes high. The guy at the service shop first opened the motor cover and plugged in new mount along with new cable directly to motor and nothing improved. Then he replaced Intuvia mount without replacing the cables (as recommended in the manual) and... nothing improved The bike still wouldn't turn on most of the times using button on the display. I can't tell if this fixed mid-ride cut-offs because these happen rarely and almost without any pattern. I rode for half an hour on a VERY bumpy terrain outside the shop and everything seemed fine, no cut-offs, but bike still wouldn't power on every time using power button on the display. Maybe cut-offs were related to the mount, yet they are so random that it was hard to tell. Then he gave me another (used) Powerpack 500 battery to try out. Yes, he was an extremely nice guy and determined to find the culprit. And suddenly... everything worked perfectly The bike turned on every time using display button, no matter how much we tried to "abuse" it. I left my battery at the shop and we agreed that I try this one for a few days. During one-hour ride home (~17km) everything was fine. The bike turns on every time, whether I use battery or display button. I'm truying my best to torture-test it and it works flawlessly. Cut-offs are still to be tested more. Maybe, just maybe, these two problems are unrelated, but I highly doubt it. For now my unfortunate solution seems to be faulty battery.

I know this is an old thread but I still haven's found a solution. I wanted to replace the mount but COVID-19 situation made it dificult for me to obtain one. Now new riding seson is here and I'm once more able to order the given part, I was just wandering did you reuse the existing cable (which connects Intuvia mount to the motor) or did you also change the cable? I'm asking because changing just the mount and keeping the cable seems infinitely easier and doesn't require additional tools (such as crank puller).

I know this is an old topic, but I don’t seem to find anywhere a 100% working solution to the problem OP has described. I also have the same problem combined with intermittent power cut-off. My setup (KTM bike, 2019): Intuvia display Intuvia mount with 3 golden pins on the left and 4 silver on the right Powerpack 500 battery Performance Line CX drive unit (Gen 2, 2019) Issues: Most of the time the bike won’t power on using power button on the display. However, it always turns on using power button on the battery itself. During the ride the motor sometimes turns off (unrelated to the riding conditions such as bumps), but Intuvia stays turned on. It eventually recovers by itself or turns off completely. Most of the time when I try to power on the bike using power button on the Intuvia display, Intuvia display turns on (glowing) and it shows last remembered battery charge. It doesn’t show “Performance Line CX”, it doesn't show current speed (“0.0” after boot) and it doesn’t show lights-on status (if the lights were left on last time). Only after turning on correctly and completely (usually using power button on the battery) Intuvia will show new battery level (e.g., if the battery was charged after last shutdown) and lights-on status (again, if lights were left on during last shutdown). The other issue is that during the ride the motor turns off but Intuvia stays turned on (not showing speed or lights status just like during irregular boot). Sometimes it helps to quickly slide it out of the mount and put it back in while in other situations I have to stop and power it on using power button on the battery (it can be quite unsafe to try this while still riding). This sometimes happens few times during a single ride and sometimes it doesn't happen for hundreds of km. In couple of places I have found the advice to replace Intuvia mount with “new model”, shown on the picture below (see pin colors). You can also check couple of related threads: https://www.pedelecs.co.uk/forum/threads/bosch-motor-display-cutting-out.32097/ https://electricbikereview.com/forums/threads/bosch-speed-performance-system-shuts-down-mid-ride.24218/post-349640 What I tried and failed: Everything is mint condition clean, yet I cleaned it again I tried using different Intuvia display (courtesy of local Bosch service center) Playing with cables does nothing (if it were up to bad cables, I guess it would show up when I intentionally try to cause it), Battery is well in place. In fact as I said, battery turns on Intuvia every time but Intuvia fails to turn on the battery. I even checked contacts where cable from the motor connects to Intuvia (see picture). The only thing I haven’t checked of changed is the part of the mount that can’t be opened. I will probably replace it in the near future if I manage to get the “new” model and report back.

I found here that even Purion users suffer from the same problem, although it might be a completely different issue. The topic in the link is also an excellent one for all of us who suffer from this issue. Buying new Intuvia mount seems promising. I might even take the plunge, just want to try a few more DIY things, hoping there is another way rather than spending more money for something not 100% guaranteed to work.

Do you mean you replaced Intuvia with Purion? It sounds like a bit of a downgrade, but if I followed correctly, the problem we are discussing here happens only with Intuvia mounts (meaning Intuvia and Nyon displays), am I right?

Hmm, that sound like a probable solution (unfortunately, as my bike is no unde warranty, so I'd have to buy replacement part). I did stumble upon this solution in couple of places. Just of curiosity, what is the color of the pins on your display unit, not the stand itself. Here's how mine Intuvia looks:

A few years later and I realize that this problem is more common that I thought. After a full year of leaving my bike in the bedroom (annoying my wife, but I do not have a garage so...), resting around 40-60 percent charge at room temperature, as recommended for storage purposes in order to minimize deterioration of Li-ion battery, I can report the following. I decided to take it for a ride without recharging the battery and it was horrible experience. Just maybe around a mile or so, taking it to a gas station to precisely inflate the tires and a circle around the block the motor was more OFF than ON. Ok, that is a bit overexaggerating, but I definitely experienced TONS of cut-offs. My first step in attempt to remedy the problem was ONLY to remove the battery from the bike and recharge it fully. During the next ride cut-offs were SIGNIFICANTLY reduced. This gives me the impression that it is almost certain something related to internal battery wiring, whatever everyone else over the internet is saying (or at least it's part of the problem). I tried to clean the contacts, both battery and Intuvia and they were already completely clean, so no change there. And then I stumbled upon this excellent troubleshooting video by the Propel bikes (my issue with the Bosch is the first one described in the video): I started my own diagnostics. Turned the bike on, waited for speed to appear on the screen to make sure everything is connected and then: 1) I unlocked the battery (Powerpack 500) from the bike frame and started to wiggle it around. Nothing happened. Then I started to pull it out of the contacts and it took significant length to pull before connection was lost and the speed disappeared from the screen. So I'm assuring you it has nothing to do with the battery-to-motor connection. That one is very sturdy and resilient. 2) I started to slide Intuvia display until it lost connection. This one took less effort, so I'm not excluding the idea that this is maybe the culprit. I also removed the screw which came with the bike, securing Intuvia display to the mount and making it unable to move. And I also loosen the bolts as recommend in the video but I'm not sure if it's just placebo. FYI, my Intuvia mount has all contacts in "gold color", if that info is relevant. Anyway, now I get cut-offs rarely, almost exclusively related to hitting big bumps, BUT… Sometimes, when I turn on the bike, the display still doesn't show speed. At that moment, if I turn on the battery using the button built in on the battery itself, everything works fine. Bottom line is that not a single solution you find online works 100% (including applying dielectric grease and updating firmware). If you ask me, there are ways to get around this but not to FIX it permanently. Bosch design definitely failed here and they don't want to admit. I hope this will help someone Cheers!

0.1mm sounds like quite a small gap. I found this picture in the official installation manual. I double-checked gap on my bike and it is within given range. Magnet is positioned just like on the picture.

Update form the trenches First, I would like to make a short disclaimer. In my case the described issue occurs quite rarely, so take all my findings and assumptions as "statistically weak". I simply do not have enough sample data to draw any strong conclusions. I definitely managed to distinguish 3 separated issues (divided into 2 "categories" of issues): 1) Power cuts-off mid ride. I'm 99% sure it has to do with hitting a bump. I tried to remove Intuvia, cleaned it (it already looked completely clean) and put it back but the issue continues. My Intuvia display is also screwed with a security bolt so I guess that improves contact and eliminates display itself as component from the "bump" equation. I also tried removing the battery and cleaning contacts, but they were also already clean and looked like there was no visible issues I could pinpoint as a culprit. 2) Assistance is not supplied upon system start. This one is more common for me. There are 2 issues in this category: - The power doesn't kick in even after 10-20 meters of pedalling and sometimes display goes blank during this time. Starting it again (with on/off button) did the job once. Also, hitting the battery couple of times helped once. Last time this happened I manually pressed the little button located on the battery and the display immediately showed 0 as detected speed and started providing assistance. I didn't see if the battery indicator was lit before pressing the button. Maybe, somehow the system fails to turn on the battery? - The assistance doesn't start immediately but kicks in within seconds after I start pedalling. My guess is that this is related to sensor alignment and system just needs a moment to register its movement. I also might be wrong. This might be exactly the same as the previous issue, only resolves by itself quickly. Maybe there is a delay in turning on the battery because for some reason system fails to do that, and, after some default time set by Bosch, system concludes that there is no battery or tries to restart or something else (thus turning off the display). All this is just my guessing. It might be useful for all who report this issue to say which motor/display/battery combination they have. In my case it's CX / Intuvia / PowerPack 500.

Hey, don't worry. I hope you had a great time in Spain. Thanks for the answer. I havn't had any "major" issues since I wrote my last post, but my theory so far is that either speed sensor needs few meters of bike movement to "react" (if the cut-off is very short) or some contact gets loose i.e. battery of Intuvia display (if cut-off is a bit longer and contact needs to be reestablished). If and when it happens again I will pay more attention and try to test my theory. Let's hope I will never have the chance

Hi Phil, I'm having the same issue and I was wandering if you could share the solution here, in case someone else stumble upon this thread? Cheers!