Bosch gen 5 charger socket cover.

steve_sordy

steve_sordy

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My first Bosch powered bike.
In the bike shop, the guy showed me how the Bosch range extender fitted. I was unimpressed when the socket cover was just swivelled back and downwards to be left flapping in the air. It would be definitely in harm's way on the trail, to be snagged and swept aside by all sorts of shrubbery and near misses, never to be seen again. :censored:

On Sunday, only my second ride, I had an off into bushes (an evil mix of Gorse and Brambles). Despite not using the range extender, the cover was left hanging off the bike frame. It was dangling by the thin piece of rubber that secures it to the frame. If it had been raining, or the shrubbery rain sodden, the charger socket would have been exposed to the wet.

Today I washed the bike; no hose just a watering can. When I had dried the bike I peeled back the rubber cover over the charger socket just to see if it was wet or dry inside. It was wet! What a useless cover if it can't keep the wet out! :mad:

I swivelled it down to dry the inside of the cover and it came off in my hand! So easily dislodged when in the same position it would be if I had been using the range extender.

It was a right swine to get it back in. It will not simply push back in. There is a rubber spike that acts as a hole finder, then comes a flange around the spike that is supposed to lock into place on the other side of the hole. It would not go in. I shone a strong light onto the end of the cover and I could see that on the flange is a small spike sticking out at right angles that appeared to be preventing "simply pushing it back in". I had to push the spike in first with a metal pick, the sort that you can use to remove oil seals, or foam rings from inside forks. Once the spike was in the flange could be pushed in.

I am deeply unimpressed with the design of this absolutley essential cover. It does not appear to keep water out, using the Bosch range extender puts the cover in harm's way and once in harm's way, it is easily dislodged and potentially lost for ever! :mad:

I have already decided what I will do if this happens on the trail - a good piece of Duct tape, the universal fixer. And I am going to buy a couple of replacements. While the cover was off, I copied down the part numbers on the inside; two lines. Just in case you have lost yours or believe that you be about to do so!

BOSCH EB1212001B​
1037EB0080​

Has anyone else had this problem? How did you fix it? Is this a design that has stood the test of time since Gen 1, or is a recent innovation? Any suggestions?
 
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I think they’re only good for keeping out coarse mud/grit. The socket itself is water ingress allowing - I agree it shouldn’t be… but if after cleaning you use an airline to remove any remaining water it should be reasonably clean leave to dry. I might use some WD40 Switch/contact cleaner on mine to preserve the plating on the contacts…

I was a bit surprised when I first removed the motor cover on my Vala, none of the wiring is secured/wrapped/tied like you’d expect but heho this the cycle industry were talking about!! (I’m from an automotive discipline…)
 
steve_sordy said:
My first Bosch powered bike.
In the bike shop, the guy showed me how the Bosch range extender fitted. I was unimpressed when the socket cover was just swivelled back and downwards to be left flapping in the air. It would be definitely in harm's way on the trail, to be snagged and swept aside by all sorts of shrubbery and near misses, never to be seen again. :censored:

On Sunday, only my second ride, I had an off into bushes (an evil mix of Gorse and Brambles). Despite not using the range extender, the cover was left hanging off the bike frame. It was dangling by the thin piece of rubber that secures it to the frame. If it had been raining, or the shrubbery rain sodden, the charger socket would have been exposed to the wet.

Today I washed the bike; no hose just a watering can. When I had dried the bike I peeled back the rubber cover over the charger socket just to see if it was wet or dry inside. It was wet! What a useless cover if it can't keep the wet out! :mad:

I swivelled it down to dry the inside of the cover and it came off in my hand! So easily dislodged when in the same position it would be if I had been using the range extender.

It was a right swine to get it back in. It will not simply push back in. There is a rubber spike that acts as a hole finder, then comes a flange around the spike that is supposed to lock into place on the other side of the hole. It would not go in. I shone a strong light onto the end of the cover and I could see that on the flange is a small spike sticking out at right angles that appeared to be preventing "simply pushing it back in". I had to push the spike in first with a metal pick, the sort that you can use to remove oil seals, or foam rings from inside forks. Once the spike was in the flange could be pushed in.

I am deeply unimpressed with the design of this absolutley essential cover. It does not appear to keep water out, using the Bosch range extender puts the cover in harm's way and once in harm's way, it is easily dislodged and potentially lost for ever! :mad:

I have already decided what I will do if this happens on the trail - a good piece of Duct tape, the universal fixer. And I am going to buy a couple of replacements. While the cover was off, I copied down the part numbers on the inside; two lines. Just in case you have lost yours or believe that you be about to do so!

BOSCH EB1212001B​
1037EB0080​

Has anyone else had this problem? How did you fix it? Is this a design that has stood the test of time since Gen 1, or is a recent innovation? Any suggestions?
Click to expand...
What i do is put a bit of tape over the socket hole and put the flap back over it,just peel it off when you recharge,id cut off the spike drill a small hole and put a self tapping screw on it,worked for me.
If you need cube parts,westbrook cycles are the go to peeps,they can get you anything,from single bolts to bearings etc.
 
The cover on my Mondraker came off during the 1st week of ownership.
It's still off 5 months later, because it seems like I have to drop the motor to get to the inside and reattach it.
 
I test rode the Santa Cruz Vala when it had just come out to see if it was a noticeably better bike than my trusty Trek Rail which has the pre-smart gen 4 Bosch system. Yes it was a great bike, and the new motor was quieter, but I too was amazed at the crappy rubber charger flap. I also rode a Pivot Shuttle AM for a week and was constantly trying to get the bloody thing to stay in place and stop falling out. I respect the Bosch brand and like their CX motor, but they have repeatedly let themselves down in terms of some of the "peripheral components" such as this charge port flap and their uninspiring initial series of handlebar controllers and displays.
 
steve_sordy said:
Has anyone else had this problem? How did you fix it? Is this a design that has stood the test of time since Gen 1, or is a recent innovation? Any suggestions?
Click to expand...
I find this cover to be the best Bosch had over some time now.

It is designed not to fall out easily. If you want to remove/reinsert the cover you need to open and then turn it 90°. That will align the small 'spike' with the corresponding cutout. Now you can simply press the rubber into the hole, turn it back 90° and it's done. There are no tools needed.

For use with a PowerMore extender I would probably remove it for that ride.

When closing the cover make sure the two protruding bits align with the opening in the socket. You should feel the cover snap into its final position which will prevent it from opening unintentionally.

I never lost one in more than five years but it might be a good idea to buy a spare to fight cover loss anxiety.
 
I think the charging socket is alot better then my previous gen 4 bike.
It doesnt slide open or falls off and has a click sound when open or close
17791961580515432697591890261003.webp
 
Sander23 said:
I think the charging socket is alot better then my previous gen 4 bike.
It doesnt slide open or falls off and has a click sound when open or closeView attachment 184774
Click to expand...
This is not the same flap as on the Vala and Shuttle AM that I have ridden. So probably also not the same as the one that the OP is complaining about. Looks like some bike manufacturers are making their own flap designs.
 
Charging port covers vary with each manufacturer... I didn't realize Bosch had its own. My last Shimano eMTB had a Darfon battery/charger and the tiny rubber cap didn't last long before it ripped off.

My Norco Range has a decent spring-loaded plastic cover with rubber seal... its not perfect, but better. Like this:

1779198708546.webp
 
Sander23 said:
I think the charging socket is alot better then my previous gen 4 bike.
It doesnt slide open or falls off and has a click sound when open or closeView attachment 184774
Click to expand...
Like that flap design. Our 2022 Trek Rail 5 covers are crap, they sort of wiggle in and out. Won't keep water out but otherwise they work (but do need patience to close them).
 
I don’t understand why we don’t have a universal charging method like most EV’s have. How many different sockets and plugs are there for our bikes? Money I suppose.

I always thought a magnetic induction method would be nice. Similar to phone pads. For the time being I have 3 different types of chargers and a rats-nest of power cords.

Water ingress in the socket cavity is always a concern.

Rant over. 🙄
 
Last edited:
I think the actual charger/port is universal. It’s just the cover that is different from mfg to mfg. My Yeti LTE doesn’t look like any of the above pictured. It’s just a mediocre rubber plug. Nothing special.
 
PeterHenric said:
I think the actual charger/port is universal. It’s just the cover that is different from mfg to mfg. My Yeti LTE doesn’t look like any of the above pictured. It’s just a mediocre rubber plug. Nothing special.
Click to expand...
Yes, I use the same charger for different bikes. My Cube has a relatively basic port cover that can sometimes find itself open. That always worries me as it's easy to get it wet/muddy. However my Cannondale has a properly closing weatherproof port near the stem.
 
Sander23 said:
I think the charging socket is alot better then my previous gen 4 bike.
It doesnt slide open or falls off and has a click sound when open or closeView attachment 184774
Click to expand...
If mine was like that, I doubt that I would be complaining about the design. Your cover is secured with a screw for starters. The cover would have to tear or the screw wrenched from its threads to lose the cover. Yours looks robust.
Several posts refer to bike manufacturers providing their own covers, which probably says a lot about what they think of the Bosch design!
 
steve_sordy said:
If mine was like that, I doubt that I would be complaining about the design. Your cover is secured with a screw for starters. The cover would have to tear or the screw wrenched from its threads to lose the cover. Yours looks robust.
Several posts refer to bike manufacturers providing their own covers, which probably says a lot about what they think of the Bosch design!
Click to expand...
If enough people bring it to Santa Cruz’ attention they might consider a retro upgrade. They can pull their finger out with organising more stock of the motor guards too! I think most of the industry is fully invested and about to find hard returns this year and next. So who knows what quality of service warranty and associated will provide going forward….
 
I ride a Bullit. I cut the mushroomed part of the tab off that secures the cover to the frame. I just take the cover on and off as needed. Seems to work fine. I too thought the dangly cover was a joke while using the range extender. This way I can keep the cover clean in a pocket. I ordered a couple spares because I’ll probably loose one this way. Hope this helps.
 
I have a new Cube One77 with the Gen 5 and that awful port cover with a tiny magnet that really doesn’t seal anything. However, a thin slice of an old inner tube works perfectly; takes a second to pop on, seals brilliantly and looks like it’s meant to be there. :)
 
Jbone5000 said:
I cut the mushroomed part of the tab off that secures the cover to the frame. I just take the cover on and off as needed.
Click to expand...
No way! Do you really do that or is this a joke?

The rubber flap is designed to be easily removed or inserted into the charge port frame for such times where you need it removed for riding with the range extender plugged in. The short 'mushroomed' part with the spiked protrusion to one side fits exactly into a hole with corresponding cutout on one side. The pointy rubber functions as an axle for removal.

As I mentioned before there are three simple steps to remove the flap:
  1. Open the flap just enough so that the flat rubber inserts come out of the socket contacts
  2. Turn/slide the flap about 90° to one side so that the spiked protrusion aligns with the cutout using the 'mushroomed' Part as axle (I can't remember whether you need to turn the flap clockwise or counter clockwise from the last time I did this)
  3. Gently pull the whole flap out of the charge port
Absolutely no need for any cutting, brute force or tools!

For insertion do the steps in reverse order.
 
Shark58 said:
No way! Do you really do that or is this a joke?

The rubber flap is designed to be easily removed or inserted into the charge port frame for such times where you need it removed for riding with the range extender plugged in. The short 'mushroomed' part with the spiked protrusion to one side fits exactly into a hole with corresponding cutout on one side. The pointy rubber functions as an axle for removal.

As I mentioned before there are three simple steps to remove the flap:
  1. Open the flap just enough so that the flat rubber inserts come out of the socket contacts
  2. Turn/slide the flap about 90° to one side so that the spiked protrusion aligns with the cutout using the 'mushroomed' Part as axle (I can't remember whether you need to turn the flap clockwise or counter clockwise from the last time I did this)
  3. Gently pull the whole flap out of the charge port
Absolutely no need for any cutting, brute force or tools!

For insertion do the steps in reverse order.
Click to expand...
Not a joke, bud. Try it out.
 
Shark58 said:
No way! Do you really do that or is this a joke?

The rubber flap is designed to be easily removed or inserted into the charge port frame for such times where you need it removed for riding with the range extender plugged in. The short 'mushroomed' part with the spiked protrusion to one side fits exactly into a hole with corresponding cutout on one side. The pointy rubber functions as an axle for removal.

As I mentioned before there are three simple steps to remove the flap:
  1. Open the flap just enough so that the flat rubber inserts come out of the socket contacts
  2. Turn/slide the flap about 90° to one side so that the spiked protrusion aligns with the cutout using the 'mushroomed' Part as axle (I can't remember whether you need to turn the flap clockwise or counter clockwise from the last time I did this)
  3. Gently pull the whole flap out of the charge port
Absolutely no need for any cutting, brute force or tools!

For insertion do the steps in reverse order.
Click to expand...
I may be guilty of not looking closely enough at the hole the cover spike goes into.
Tomorrow, I will lay the bike onto the lawn in the sunshine and have a really good look. :)
 
PeterHenric said:
I think the actual charger/port is universal. It’s just the cover that is different from mfg to mfg. My Yeti LTE doesn’t look like any of the above pictured. It’s just a mediocre rubber plug. Nothing special.
Click to expand...
Simple is good. The cover on my EP8 (Merida eOne Sixty) was on a horizontal surface on the down tube just in front of the shock. The cavity it was in regularly filled with watery mud. It also filled with water when I washed the bike. But as long as I cleared the watery muck out of the way before removing it, the plug never once let in water, in over five years.
 
This is very weirdly timed

I had a cube 140 action team - gen 4 - charge cover was lovely, just swivelled out the way

Now I have a cube one77 and it's garbage - it's a plastic door that opens 90degrees to the bike - so when I use my range extender it's just stuck out there ready to get snapped off


1779584809823.webp


I'm already thinking I'll just 3d print a flexible port cover or something and try to throw the original one in the bin. Very little thought put into the design of that for range extender users
 
Shark58 said:
No way! Do you really do that or is this a joke?

The rubber flap is designed to be easily removed or inserted into the charge port frame for such times where you need it removed for riding with the range extender plugged in. The short 'mushroomed' part with the spiked protrusion to one side fits exactly into a hole with corresponding cutout on one side. The pointy rubber functions as an axle for removal.

As I mentioned before there are three simple steps to remove the flap:
  1. Open the flap just enough so that the flat rubber inserts come out of the socket contacts
  2. Turn/slide the flap about 90° to one side so that the spiked protrusion aligns with the cutout using the 'mushroomed' Part as axle (I can't remember whether you need to turn the flap clockwise or counter clockwise from the last time I did this)
  3. Gently pull the whole flap out of the charge port
Absolutely no need for any cutting, brute force or tools!

For insertion do the steps in reverse order.
Click to expand...
Dude watch the video posted just now by Arminius showing your average person struggle with the cover. Please post a similar video of you replacing the cover with the ease in which you brag about. I really think your advice is bunk. My harmless advice that is dead serious is cut the tip (JUST THE TIP!!!) of the plug off and then it works great to take on and off and I ride and wash my bike all day with the cover on that way with no probs. Just saying…. Video or it didn’t happen.
 
Arminius said:
To bad SC put such a cover on a bike. You can see here around 22:30 the problem:

Click to expand...
If everyone emails Santa Cruz to say they have an issue with their pishflap. I’m sure maybe they’d consider resolving the problem!
 
Purple parznip said:
Why would i want to add extra weight,just put an 800 in it,then i would buy one!
My rides are 30 + miles,a 600 is no good
Click to expand...
Then don't buy a Vala.
Santa Cruz made a clear decision as to why they went 600 W-hr instead of 800 W-hr. They balanced the extra weight and the larger downtube against a more svelte looking bike with a shorter range, but a better riding experience for most people (ie those that don't do 30 miles plus and lots of elevation).

You might like the look of the Vala, but it's not for you. Simples!
 
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