Bosch gen 5 charger socket cover.

[GDAS]

....

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


View attachment 185126

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

I'm pretty sure the flap unclips somehow, for when you're using the extender. I remember my dealer demonstrating it (I'd showed some interest in buying an extender, but the stock 800 turned out to be plenty)

 

[sjturner2112]

I believe each bike / most makers have their own flap design, I know my Wild has socket cover that is very effective, it stays put, and is generally water/dustproof. In fact, I find it hard to pull up, and then swivel out of the way, the spring action is very tight.

 

[steve_sordy]

I'm pretty sure the flap unclips somehow, for when you're using the extender. I remember my dealer demonstrating it (I'd showed some interest in buying an extender, but the stock 800 turned out to be plenty)

If it is the same Bosch flap as mine, then it can indeed swivel out of the way and be easily removed for safe keeping, and then replaced later. I am so informed by posts on this thread.

However, I have not done this myself, yet.

I have bought two replacement covers, see previous posts. They do look good. The plug-in part does look to have a directional shape meant to go in and out in one orientation. Not randomly yanked out and forced back in like mine was (the light was poor). When the time is right, I will put my bike on the lawn in the harsh glare of sunlight and have a really good look at how it is supposed to work. All so that I can do it easily and apparently, as it is meant to be done.

 

[Shark58]

I will put my bike on the lawn in the harsh glare of sunlight and have a really good look at how it is supposed to work.

You will find a plastic frame sitting atop the charge socket with the cutout I mentioned before.
Take a look at the photo where I marked the hole with cutout into which the rubber spike will fit:

 

[Arminius]

Maybe this helps for practicing,, looks easy bit is often discussed:

Pivot Shuttle LT owners | Do we have a solution for this cheap charging port cover nonsense | Facebook

Do we have a solution for this cheap charging port cover nonsense?

www.facebook.com

Looks like the same cover?

 

[steve_sordy]

Thanks @Arminius that looks very similar to the Bosch one, but it's not the same.

 

[Joecrow]

Thanks @Arminius that looks very similar to the Bosch one, but it's not the same.

At least you can get one, on my Haibike the cap broke off and was lost the Bosch one (even with housing is not compatible with the frame. I can't find a replacement anywhere on the internet and my LBS have never stocked it and say they can't order it as Haibike (Accell) have a minimum order value for spares that is way over what the will need for at least another year!
I'm stuck with using the one shown in the attached pic from Amazon which gives some protection but regularly gets lost as I can only push fit it in the charging socket, nothing to attach it to.

 

[Bear-uk]

I decided to sort my flap out today
Took the faceplate off and then the engine cover and found a spring, but no clip. Just as well that I permanently borrowed an assortment from a previous employer

 

[Bear-uk]

Sorry about the doubled up images.( Fat finger club)

 

[steve_sordy]

At least you can get one, on my Haibike the cap broke off and was lost the Bosch one (even with housing is not compatible with the frame. I can't find a replacement anywhere on the internet and my LBS have never stocked it and say they can't order it as Haibike (Accell) have a minimum order value for spares that is way over what the will need for at least another year!
I'm stuck with using the one shown in the attached pic from Amazon which gives some protection but regularly gets lost as I can only push fit it in the charging socket, nothing to attach it to.

View attachment 185291

That is a bummer and no mistake!
What are you using in the meantime to keep oit the dust, muck and water?

The first thoughts that came to my mind was a zip tie or combination of zip ties to hold on the cover that you are using right now. Second thought was something sticky, like adhesive tape, if the cover does get lost. I have about two metres of duct tape wrapped around my mini-pump. Duct tape has so many uses, it should be called "the universal fixer".

 

[Joecrow]

The first thoughts that came to my mind was a zip tie or combination of zip ties to hold on the cover that you are using right now. Second thought was something sticky, like adhesive tape, if the cover does get lost. I have about two metres of duct tape wrapped around my mini-pump. Duct tape has so many uses, it should be called "the universal fixer".

The thingy from Amazon is made of fairly flexible rubber so it does hold in the socket quite well but any knock or brush with anything and its gone. Some Duct tape over it would work but I often use a Powermore extender so I don't want it to be too permanent. Using the extender is the real problem as whatever type of cap to have won't be in the home position and will be loose and venerable to being torn off.

 

[steve_sordy]

The thingy from Amazon is made of fairly flexible rubber so it does hold in the socket quite well but any knock or brush with anything and its gone. Some Duct tape over it would work but I often use a Powermore extender so I don't want it to be too permanent. Using the extender is the real problem as whatever type of cap to have won't be in the home position and will be loose and venerable to being torn off.

I wasn't thinking of duct tape over the cover, but something made of zip ties that can be slid to the side to release the cover for charging. The duct tape was for once you have lost the cover and are out on the trail, just to keep out debris/water from the socket.

As for when using the range extender, I am thinking of removing the cover and putting it in my pocket!

 

[Joecrow]

As for when using the range extender, I am thinking of removing the cover and putting it in my pocket!

That's what I do with the Amazon thingy but I have lost it from there also.

I wasn't thinking of duct tape over the cover, but something made of zip ties that can be slid to the side to release the cover for charging.

Oh right, I've got some velcro strip with buckles, should be a bit more flexible for release than zip ties, I'll give that a try thanks.

 

[Maxi]

Whilst I don't have an issue with the charger cap, I do have a solution even though it's not needed ! I carry a small toolkit in a Race Face Tool Stash which attaches to the lower part of the seat tube. It naturally covers the charger cap and can be slid up enough (without removing) to charge the bike. Big enough for my multi-tool, chain tool, quick links & bacon strips / applicator.

 

[emtbPhil]

Yeah it does but by semi bending a really flimsy plastic pin

I've bought an entire spare cover now for £6 - I have a feeling it will be getting replaced fairly regulary

During the week I don't use the extender at bike parks, but then most weekends I'm out doing 3-4hr rides and use it every time - so it's constantly on and off the bike

 

[steve_sordy]

Yeah it does but by semi bending a really flimsy plastic pin

I've bought an entire spare cover now for £6 - I have a feeling it will be getting replaced fairly regulary

During the week I don't use the extender at bike parks, but then most weekends I'm out doing 3-4hr rides and use it every time - so it's constantly on and off the bike

What bike is that referring to?

 

[Braz117]

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.

I bought a Vala and I to was a little concerned about the rubber flap that covers the charge socket. After having the bike for a could months and washing it regularly it does a good job keeping the water out. Lets see how it does long term.

 

[dezzracer]

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.

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!

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!

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?

As you mentioned duct tape is your best and easiest fix.

 

[Rockhopper70]

Interesting thread this, and I’m also now a member of the charging port cover detachment club!!!

After a ride in the nadgery lakes with the range extender, I heard my cranks glancing the charging port cover. I tried to adjust it to keep it out of the way but to no avail, and one side of the sprung hinge failed. I now have a cover, with one magnet, that doesn’t seem strong enough to keep it on. I had to gorilla tape the cover over the socket when I ran without the RE the following day.

Incredibly, however, and when googling for ideas to improve things, I had commented on this poor design on PinkBike in 2024! I wish I could predict the lottery numbers….

It’s going to be £25 for a new one shipped. But that won’t solve the problem and could happen on the first ride out!

But, and let me have a sense check here, if I buy another PowerMore cable and cut the lead off and dremel off the electrical tabs, I’ll be left with a “cover” that positively locks into place and should be as, if not more, waterproof than the flap? Is there any reason that won’t work if the electrical connectors are removed?

 

[GDAS]

if I buy another PowerMore cable and cut the lead off and dremel off the electrical tabs, I’ll be left with a “cover” that positively locks into place and should be as, if not more, waterproof than the flap? Is there any reason that won’t work if the electrical connectors are removed?

as a simpler alternative, how about these 3D-printed plugs? (for clarity, I know nothing about them, there may be better ones out there)

 

[Joecrow]

as a simpler alternative, how about these 3D-printed plugs? (for clarity, I know nothing about them, there may be better ones out there)

Amazon have something similar, see an earlier post by me but these could be better, can you post a link please?

 

[GDAS]

Amazon have something similar, see an earlier post by me but these could be better, can you post a link please?

here you go https://www.ebay.co.uk/itm/236668279487

EDIT: link doesn't seem to work from here, but it's ebay item 236668279487

 

[Joecrow]

But, and let me have a sense check here, if I buy another PowerMore cable and cut the lead off and dremel off the electrical tabs, I’ll be left with a “cover” that positively locks into place and should be as, if not more, waterproof than the flap? Is there any reason that won’t work if the electrical connectors are removed?

Nice idea, I think I would be tempted to leave the cable attached and fix it securely to something. That way it won't fall out of my pocket or get left somewhere(wouldn't be the first time) when the PowerMore is connected.

 

[Rockhopper70]

Thanks for the links. I’ve just put a warranty claim in with Canyon and cited that PinkBike article. I’ll see how that plays out but it’s not going to stop it happening again even if they do replace it. I suspect that due to the awfully steep and rocky trails around the Lakes, that my body and foot positioning while riding has caused this.

Edit, to add, those covers look ok but the genuine items have a rubberised seal within them and I suspect those 3d printed items are “rigid”.