Shimano EP8 stops working while riding - no fault in log?

My cutouts seem to be getting worse lately
I have had this where the motor shuts off for 5 minutes while it and or battery cools before bike will power on. When this happens bike shuts off more than twice in 25 miles. but when its more than twice draining a full battery, you know its time to replace.


This is when rubbing alcohol on motor connection helps and brings the shut off number down , I have only had the new battery shut off once, but my ep 801 is damaged after 3,800 miles. So that may be the cause because of excessive draw.
 
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Did you get your battery replaced under the recall?

Just got mine a few weeks ago, mine was shutting off twice a ride, new battery changed that
Mine is the 720 battery, and those are pushed out to September (at least).
 
This system is so finicky, if you wash your bike. that will start random shut offs. They are not even water resistant
Yes, this unfortunately is absolutely true and I completely agree.
Especially on the CANYON bike, the Rosenberger plug is not water resistant and rigid enough like it should be on a well developed MTB.
However, this is also the reason why I suggest not to wash your bike at all (or at least don´t use any water close to the battery and motor).
Due to this I am never cleaning my bikes with water, but only "dry". That is sufficient for me.
And if your bike gets wet otherwise, then remove the battery from the bike and place the bike and battery inside a warm room overnight, clean contacts instantly and so avoid any corrosion and resulting contact issues or leakage currents caused by water, mud, dirt or other influences the Shimano STePS system unfortunately does not like.
 
never cleaning my bikes

I ride in some nasty mud in winter, no choice

I have a buddy who never washes his bike, but it still shuts off now and then. But much much less.

If I dont wax chain every ride, I chain suck on chainring.

I didnt mention but I ride high miles, im at 2800 for the year and have climbed 370,000 feet in elevation. So i drain a 900w battery almost every day.

The first 1000 miles was fine, so 2.5 months, after that, problem after problem
 
@Winford: Did you ever try to get in direct contact with CANYON Germany. It seems like you have a lot of "experience" in this cutoff issues and I can imagine that CANYON might be thankful to get such insider knowlege. Please try to write an email to them (if you don´t have already done this before). For sure CANYON currently still has a lot of extra work to do with the delivery if their replacement batteries, but if they are a "caring" company (which I still hope CANYON is) then they should be willing to listen to you and so get the chance to improve their batteries and cable harness (at least in the future) or maybe also give you some good deal on future cable harnesses (maybe in bulk quantities). Seriously.
 
intermittent power loss problem. For 14 months. ep801 replaced once after 1400 miles, 6000 miles now. 3 battery to motor rosenburger cables have been replaced.

Just got the recalled battery in it and last two rides it has not shut off yet.

Canyon spectral on CF8. feels like it dropped power 2 weeks ago about 20%. then I got the new battery and that increased power 10% so now bike feels underpowered by 10% which may be weaker batteries that came with recall, or my motor is starting to take a dive
FWIW, my buddy got the new 900wh battery for his Spectral:ON... and he is still getting random shut offs! So whatever the problem is, Canyon hasn't addressed it with the new batteries.
 
FWIW, my buddy got the new 900wh battery for his Spectral:ON... and he is still getting random shut offs! So whatever the problem is, Canyon hasn't addressed it with the new batteries.
As written before - these random shut offs are mostly related to cabling issues between the components (e.g. between battery and drive unit) and not the components itself...
The battery was replaced by CANYON due to some battery housing material issues and related cracking possibilities and this issue has nothing to do with any sporadic shutoffs of the bike.
These sporadic shutoffs were common on many Shimano STePS based bikes and so this is not a CANYON only related issue.
Please do not mix causes and effects!
Also please tell your buddy to be very, very patient and to take his time and to carefully check all cabling and contacts on his bike with perfect ambient light and a good magnifier (e.g. via a good smartphone based camera) and he finally will succeed to find the culprit. ;)
 
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Canyon hasn't addressed it with the new batteries.
and my engine was failing, and being replaced under warranty again. So who knows what will happen when I can ride it again. been in shop 2 of the 14 months ive owned it
 
Same issue here, bike shuts down during riding randomly after 3 months after installing a new EP801 motor, no error codes. I have the standard Shimano BT-EN806 battery.

First I tried replacing the motor-battery harness (BM-EN801) but it only helped for 10 days.

I have found the root of the issue: On the motor side the right upper pin of the battery-motor connector turns golden (some kind of corrosion?) for some reason (probably not related to humidity).

golden_pin.jpg


I cleaned the pin with an electric toothbush + contact cleaner spray.
I had to brush for 5-10 minutes until it had the same color (silver) as the other upper pin.

The bike worked fine for over 2 weeks after cleaning the pin, after which the bike was shut down once again and upon inspection the pin is back to golden, so I have to clean it again.

Is it perhaps a material defect of certain EP801 motor batches? My unit 4th (year) & 5th serial (month) letter is VI which means the motor was manufactured in September 2023.

Never had this issue with the earlier EP800 (4 years of riding, even with washing & riding in wet) which uses slightly thicker pins.
 
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Whelp, my buddy's bike won't turn on now, so he's waiting for a new harness from Shimano. I, on the other hand, threatened to sue Canyon and they gave me a full refund on my bike!! So no more Shimano for me.
 
Please also check this link and especially this YouTube - video from Propain which will give some quite clever advice with an adhesive foam pad for securing the main plug on the drive unit to avoid any loose contacts (due to ongoing vibrations while riding) and increased contact resistance which then can create excessive heating and so damage the connector.
This "Rosenberger" connector seems not to be very wisely choosen from Shimano for the DU-EP600 / DU-EP801 drive units regarding the vibrations and high currents which might occur on such a drive unit while riding on the long run.
This connector also has no mechanical securing mechanism (like e.g. the former drive units from Shimano all had).
Unfortunately, the silver mechanical handle on the plug for the DU-EP600 / DU-EP801 has not any mechanical latching intention at all, but only is designed for manually unplugging the plug (see on page 34 of this document):

1759266722937.png
 
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Please also check this link and especially this YouTube - video from Propain which will give some quite clever advice with an adhesive foam pad for securing the main plug on the drive unit to avoid any loose contacts (due to ongoing vibrations while riding) and increased contact resistance which then can create excessive heating and so damage the connector.
This "Rosenberger" connector seems not to be very wisely choosen from Shimano for the DU-EP600 / DU-EP801 drive units regarding the vibrations and high currents which might occur on such a drive unit while riding on the long run.
This connector also has no mechanical securing mechanism (like e.g. the former drive units from Shimano all had).
Unfortunately, the silver mechanical handle on the plug for the DU-EP600 / DU-EP801 has not any mechanical latching intention at all, but only is designed for manually unplugging the plug (see on page 34 of this document):

View attachment 168928
Great info, thank you.

So if the connector contact is inadequate, the contact resistance is increased which leads to overheating due to high currents and the pin turns golden, which increases the pin diameter. This in turn ruins the connector of the EP801 motor-battery harness (BM-EN801), so that even if you clean the golden pin the contact will be too lose and the issue will return (the upper round hole here is the counterpart of the golden pin, notice how it's worn out and of larger diameter versus the other one):
battery harness ruined.jpg

Compare this to the earlier generation EP800 connector, which is still as good as new after 4 years of usage!
EP800 connector.jpg


Therefore in order to fix the shut down issue properly:

1) Order a new motor-battery harness (BM-EN801), don't install it yet !
2) Carefully clean the right upper pin of the motor-battery plug with a contact cleaner and 10 minutes of brushing with a modern electric toothbrush that has the new micro vibration technology (such as Braun iO series).

Before and after cleaning:
pin_dirty_again.jpg
pin_after_cleaning.jpg


3) Install the new motor-battery harness (gotta remove the motor for this, no need to remove cranks).
4) Use a piece of foam as shown in this video to keep the motor connector fully secured.
5) (Optional) Send some strongly-worded feedback to Shimano how they managed to ruin a perfectly robust connector of EP800 in their updated EP801 motor...
 
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Today my 801 turned off 2 times without any reason or error code, I'll check this connector, thx for feedback, easy fix !
 
Today my 801 turned off 2 times without any reason or error code, I'll check this connector, thx for feedback, easy fix !
Has your connector pin changed the color as well ?
 
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Can anyone measure the resistance between the two bottom contacts on the rosenberger connector?
That would be a huge help. I have a Spectral:On with ep8 and have also had lots of power cut outs. Long story but now out of warranty and trying to fix it myself. I think these bottom two contacts go to a thermistor in the motor connection, not into the motor itself. I'm trying the replace the thermistor with a resistor to get it to power up but no luck so far.
Great info, thank you.

So if the connector contact is inadequate, the contact resistance is increased which leads to overheating due to high currents and the pin turns golden, which increases the pin diameter. This in turn ruins the connector of the EP801 motor-battery harness (BM-EN801), so that even if you clean the golden pin the contact will be too lose and the issue will return (the upper round hole here is the counterpart of the golden pin, notice how it's worn out and of larger diameter versus the other one):
View attachment 168931
Compare this to the earlier generation EP800 connector, which is still as good as new after 4 years of usage!
View attachment 168933

Therefore in order to fix the shut down issue properly:

1) Order a new motor-battery harness (BM-EN801), don't install it yet !
2) Carefully clean the right upper pin of the motor-battery plug with a contact cleaner and 10 minutes of brushing with an modern electric toothbrush that has the new micro vibration technology (such as Braun iO series).

Before and after cleaning:
View attachment 168932View attachment 168930

3) Install the new motor-battery harness (gotta remove the motor for this, no need to remove cranks).
4) Use a piece of foam as shown in this video to keep the motor connector fully secured in the future, which prevents the issue returning after a few months.
5) (Optional) Send some strongly-worded feedback to Shimano how they managed to ruin a perfectly robust connector of EP800 in their updated EP801 motor...
 
Has your connector pin changed the color as well ?
Mine look like carbon not metal. But if bike shuts off 5 times, cleaning with rubbing alcohol will reduce it to 2 times

I have 2 or 4 round pins.

No motor and new battery and new Rosenberger cable, still shuts off
 
I think these bottom two contacts
So the battery and motor have thermal protection, and they both are connected via the motherboard in the battery. So if the motor has to much draw, it will overheat the battery, and visa versa. You can pinpoint which one is failing because the leds blink on battery when its a battery thermal failure, which dirty contacts can cause. So you are only screwing with half the problem. Now all that is inside the motor, and if you split the cases, you will brick the motor. So you can stop thinking about going down the road your on.
 
Hello to all!

Can anyone tell what I can try next?

I bought broken 590km drived EP800 motor for spare parts. I checked first what is problem in this motor and checked it with PCE02 and there is no any error codes. Error check routine passed and all sensors seems working. Then I tested it with display connected, confirmed that cadense sensor working and all seems to be normal but motor no assist, maybe it must assist with boost mode short time without speed sensor (before I tested it with speed sensor connected too). Motor seems working too because walk mode works fine! Everything seems to be OK but no assist. I try downgrade firmware but Etube V4 doesnt work anymore with this (motor already updated to 4.2.0) and then try only reflash 4.2.0 but nothing changes.

I think this must be firmware problem, I read from somewhere that some motors are locked if tried to derestrict and motor is sensed this, is this true? All distance (590km) in motor was in trip too and max speed showing 99,9km/h, I was thinking is this come before or after motor stop working. If shimano can lock motor in that situation its possible to unlock?

Is it possible to downgrade 4.2.0 firmware some trick?
 
Hello to all!

Can anyone tell what I can try next?

I bought broken 590km drived EP800 motor for spare parts. I checked first what is problem in this motor and checked it with PCE02 and there is no any error codes. Error check routine passed and all sensors seems working. Then I tested it with display connected, confirmed that cadense sensor working and all seems to be normal but motor no assist, maybe it must assist with boost mode short time without speed sensor (before I tested it with speed sensor connected too). Motor seems working too because walk mode works fine! Everything seems to be OK but no assist. I try downgrade firmware but Etube V4 doesnt work anymore with this (motor already updated to 4.2.0) and then try only reflash 4.2.0 but nothing changes.

I think this must be firmware problem, I read from somewhere that some motors are locked if tried to derestrict and motor is sensed this, is this true? All distance (590km) in motor was in trip too and max speed showing 99,9km/h, I was thinking is this come before or after motor stop working. If shimano can lock motor in that situation its possible to unlock?

Is it possible to downgrade 4.2.0 firmware some trick?
Please use the latest version 5.4.4 of the Windows based E-Tube-Project-Professional software (see here) and create a so called service report via the lower left button in the "MAINTENANCE" view and ideally post this PDF document here to get some overview of the drive unit (and connected components).
I don´t think that your current situation has anything to do with the currently installed motor firmware but rather has to do with a hardware issue or configuration problem...
 
Please use the latest version 5.4.4 of the Windows based E-Tube-Project-Professional software (see here) and create a so called service report via the lower left button in the "MAINTENANCE" view and ideally post this PDF document here to get some overview of the drive unit (and connected components).
I don´t think that your current situation has anything to do with the currently installed motor firmware but rather has to do with a hardware issue or configuration problem...
I have another laptop where is that newest E-Tube and with this I test rewrite firmware. I don't get that report but the error check function passes fine (No internal failures, Torque CAN be detected, Cadence CAN be detected and light works). Motor is uninstalled so there is no any other components but battery. Tested with my E-FAT's display and speed sensor with jumped straight wire to motor. (In my bike is about same age EP800 motor so components must be compatible and bike is fully working so components are fine).

Edit: This spare part motor is from quitting bike shop and they are change it to new one at original so I think they are tested it too with their own ways and components.
 
I have another laptop where is that newest E-Tube and with this I test rewrite firmware. I don't get that report but the error check function passes fine (No internal failures, Torque CAN be detected, Cadence CAN be detected and light works). Motor is uninstalled so there is no any other components but battery. Tested with my E-FAT's display and speed sensor with jumped straight wire to motor. (In my bike is about same age EP800 motor so components must be compatible and bike is fully working so components are fine).
Thanks for this additional information - however, as written before, please create and post the requested service report!
If you are not willing to do so, (at least) I will not be willing to assist further in this issue. You also can connect the (new, "defective") DU-EP800 drive unit solely (without any other components) to your SM-PCE02 interface and create this requested service report - in this case, the drive unit will be solely powered from your computer via the interface.
 
I can take it but it goes to next week. That is good to know it can take power from PCE device, easier to check. Before I connected to battery with spare wiring.
 
Can anyone tell what I can try next?
Nothing can be done, its faulty electronics in the battery from Shimano. Its just a terrible design from people with no honor. The problem is intermittent which makes it difficult to pin down. My best guess after 9000 miles and 1,300,000' of elevation in 2 years, is as follows. for the EP801. The Rosenburger connecting causes excessive intermittent resistance which throws the battery into a protection mode it thinks its being overdrawn. So these bikes have two different thermal protection sensors. One in the battery, and one in the motor. And one effects the other, so its possible to trip both on any given ride. Cleaning the terminal where the rosenburger cable attaches to the motor definitely helps but its temporary. Im on my 3rd motor 4rth Rosenburger cable, and second battery chasing this problem. Id list myself as a top rate mechanic but im limited to reporting since this was all done under warranty repairs and a battery recall. With all new components, the bike still shuts off, last rde yesterday it shut off 4 times, and battery showed the error code top led and bottom led lit each time. The last 4 rides it worked perfect for the full battery discharge. Before that shutting off twice a battery cycle. Usually when you get past the 2 cycles it goes downhill from there, and once your in the 3+ shutdowns you will start tripping the motor thermal protection which takes 5 minutes or so to cool before the bike will power on. If bike does not turn on instantly after either shut down, pull rosenburger cable and look for codes on battery. If they exist, press power button with rosenburger cable off, This restarts battery and often clears the code so the bike will start up again, provided its not the motor. anytime past 2 shutdowns a cycle is also a sign the rosenburger cable needs to be replaced. we sold all our friends these rigs so 7 in total. Most make it about 600 miles before they get the intermittent shut downs which slowly get worse, o matter what is done. Until cable is replaced. may not help you and your EP800 issues. But I hate shimano now and will use sram when possible. I bought an Amflow 1900 miles, and its been twice the fun and bullet proof, charge and ride, charge and ride. It just works. shimano sucks
 
Nothing can be done, its faulty electronics in the battery from Shimano. Its just a terrible design from people with no honor. The problem is intermittent which makes it difficult to pin down. My best guess after 9000 miles and 1,300,000' of elevation in 2 years, is as follows. for the EP801. The Rosenburger connecting causes excessive intermittent resistance which throws the battery into a protection mode it thinks its being overdrawn. So these bikes have two different thermal protection sensors. One in the battery, and one in the motor. And one effects the other, so its possible to trip both on any given ride. Cleaning the terminal where the rosenburger cable attaches to the motor definitely helps but its temporary. Im on my 3rd motor 4rth Rosenburger cable, and second battery chasing this problem. Id list myself as a top rate mechanic but im limited to reporting since this was all done under warranty repairs and a battery recall. With all new components, the bike still shuts off, last rde yesterday it shut off 4 times, and battery showed the error code top led and bottom led lit each time. The last 4 rides it worked perfect for the full battery discharge. Before that shutting off twice a battery cycle. Usually when you get past the 2 cycles it goes downhill from there, and once your in the 3+ shutdowns you will start tripping the motor thermal protection which takes 5 minutes or so to cool before the bike will power on. If bike does not turn on instantly after either shut down, pull rosenburger cable and look for codes on battery. If they exist, press power button with rosenburger cable off, This restarts battery and often clears the code so the bike will start up again, provided its not the motor. anytime past 2 shutdowns a cycle is also a sign the rosenburger cable needs to be replaced. we sold all our friends these rigs so 7 in total. Most make it about 600 miles before they get the intermittent shut downs which slowly get worse, o matter what is done. Until cable is replaced. may not help you and your EP800 issues. But I hate shimano now and will use sram when possible. I bought an Amflow 1900 miles, and its been twice the fun and bullet proof, charge and ride, charge and ride. It just works. shimano sucks
You are absolutely correct regarding the newer DU-EP801 drive unit ("generation 2") of your bike (see also e.g. this German forum post of a colleague of us with some pictures of a YT bike with DU-EP801)!
However, the reported drive unit of @aFox is an older DU-EP800 drive unit type and the "electronic ecosystem" (battery including battery management system BMS, Shimano STePS components, cabling harness and attached connectors, firmware, etc.) is complelty differnt on these 2 drive unit types, so your experience with the DU-EP801 is very valuable but does not match exactly to a DU-EP800 drive unit...
 
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Yes understood, buddy rides the EP800, but still think the battery electronics must have a similar pattern, because shimano bikes seem to shut off quite often
Yes, that is true, but mostly the real culprit in such situations on a Shimano STePS system ist the cabling harness between the drive unit and the battery or the contacts of the battery, cabling harness or drive unit. Only in very rare cases the battery or the drive unit itself is the problem. However, mostly bikeshops replace drive unit and battery first and then at the end realize that the thing "in between" is causing the issue...
 
"in between" is causing the issue...
Think about this, the electronics in the motor and battery are the one commonality in both Steps systems that have identical issues.

Both of these faulty engineered products put too much strain on the cables between, so the cable looks like the problem, when in fact it is a symptom. Other brands have used the same 2 different battery to motor cables designs, without issue. And the fact both shimano cable designs have severe issues, shows shimano is the problem, not the cable or connections. I have had band new cables cause issues, so it factually is a shimano design issue, not a cable wear item. The electronics in the battery flip the heat sensors which shut the battery off, and sometimes the motor heat sensor. Part of this issue is shimano did not want their bikes burning houses down, so they played it ""to safe"" regarding thermal management.
 
So my fix above worked for 8 months of winter riding every day without a single shutdown.

Today, the first longer (1h30mins+) ride in a warmer weather (20C+) caused a shut down, and also a second time today evening after just a 2min ride (after the bike was being charged for 1 hour).

Upon inspection, the right upper pin has once again turned to gold (oxidized), I cleaned it with contact cleaner spray and 5+ minutes of electric toothbrushing and the silver color has returned.

I also applied this compound: SR1

It's designed to prevent oxidation on aluminium, steel and copper conductors, so not 100% sure if it works on this Shimano Rosenberger plug pin, as it could be silver coated.

I will report if the issue returns, hopefully I'll get at least a few months without shutdowns.

Once the shut down happens, often the bike won't turn back on using the power button or at least you have to wait for several minutes.
What I do is put a twig (thick enough so that it doesn't snap) between the chainring and the right pedal and swiftly turn the pedals backwards for a few times.
Then wait a few seconds and after this the bike turns back on using the power button.
 
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