Bosch Active Line (Plus)

Below you will find the technical specifications of all Bosch e-bike batteries. The best-known name in the range is the Bosch Powerpack, which comes in two versions. The more popular of the two is the Bosch rear rack battery, closely followed by the Bosch frame battery.

The main difference between the Bosch Active Line and the Active Line Plus lies in performance and in how the bike rides:

1. Maximum assistance level: Both systems give you plenty of assistance, but the Active Line Plus goes up to 270%, against 250% for the Active Line.

2. Drive torque: The Active Line Plus has a higher maximum drive torque of 50 Nm, compared with 40 Nm for the Active Line. That makes the Active Line Plus the stronger motor, which you notice most on hilly rides.

3. Ride feel: The Active Line has a harmonious ride feel. The Active Line Plus is both harmonious and dynamic, so it feels stronger and more responsive while you ride.

4. Weight: The Active Line Plus is slightly heavier than the Active Line, which reflects its sturdier build and its higher power curve.

Tuning kits and speed chips exist that raise the standard 25 km/h limit of a Bosch Active Line or Active Line Plus e-bike. They do this by manipulating the speed data that is sent to the limiter and the display. We do not recommend it. A tuned e-bike is no longer a pedelec under EU rules, so you may not ride it on public roads, and the warranty and your insurance cover can lapse. The parts also wear faster because of the higher speed, and a software update from Bosch can lock the electronics.

The three familiar versions of the rear rack battery take their names from the energy each one holds, expressed in Wh. You can work out the energy content of an e-bike battery with a simple sum: take the stated battery voltage in V (volts) and multiply it by the battery capacity in Ah (ampere-hours).

An example: the Bosch battery has a voltage of 36V and a capacity of 11Ah, so 36 x 11 = 396Wh. For convenience this is rounded up to 400, and that is where the name Bosch Powerpack 400 comes from. It follows that the Bosch Powerpack 500 gives the longest range and that the Bosch Powerpack 300 has the lowest capacity in the series.

KWS Seuren specialises in re-celling and repairing e-bike batteries, so we have seen a lot of Bosch Powerpack 400 problems. This battery is used in e-bikes from many brands that fit Bosch motors. Its reliability and performance vary from one pack to the next, because the packs do not all contain the same cells. That is why some Bosch e-bike batteries develop faults that others are spared. Even so, the Bosch Powerpack 400 is a reliable battery on the whole. After years of heavy use it benefits from a cell replacement (re-celling), in which we replace all the cells with new ones. That improves both its lifespan and its performance.

The Bosch Active Line and Active Line Plus motors are reliable on the whole, but riders have reported a number of problems that are worth knowing about:

1. The motor cutting out now and then: Riders report that the motor sometimes cuts out without warning. This can often be solved by switching the bike off, removing the display and fitting it again, which restores the power supply. For some riders the problem got worse after the motor had been replaced under warranty.

2. No motor assistance: Sometimes the Intuvia display works as it should but the motor gives no assistance. The walk assist may then stop working too, and the display may not show the speed that indicates assistance.

3. Sensor problems: It has been suggested that problems with the torque sensor can lead to reduced assistance.

4. Clicking noise from the motor: Some Bosch Active Line Plus motors start to make a clicking noise after a certain number of kilometres. The problem can get worse in warmer temperatures and seems to occur whatever state the motor is in.

5. Bearing problems: A clicking noise can be caused by the bearings, such as the pedal bearings or the bearings in the drive unit. The same problem can occur in the bottom bracket or the hub.

6. Maintenance advice for bike mechanics: A bike mechanic can carry out several checks, such as the torque of the crank arm bolt, the adjustment of the drivetrain, and the bolts. It is also worth checking that the mounting bolts of the drive unit are tightened to the correct torque.

7. Problems with assistance and lights: There are cases where the motor gives no assistance and the lights do not work. This can be temporary, with the motor working normally again after about 20 minutes.

8. Interruptions in motor assistance: Riders sometimes find that the motor assistance drops out suddenly and works normally again later. This can be related to moisture or to outside factors.

9. Battery-related problems: Problems with motor assistance can sometimes be solved by replacing the battery. That points to a fault in the BMS, in the cells or somewhere else inside the battery.

The Bosch rear rack battery was supplied in 3 models from the same series. The main difference between them is the capacity. The capacities supplied include the Bosch Powerpack 300, the Bosch Powerpack 400 Wh and the Bosch Powerpack 500 Wh, which has the longest range.

Like the rear rack version, this Bosch Powerpack Frame is available in 3 variants: 300Wh, 400Wh and 500Wh. With this Bosch frame battery too, the Active Line version is the same as the Performance Line version. The only difference in this case is how it looks (the colour).

The Bosch Powertube is fitted inside the bike frame, right next to the mid-drive motor. That does away with the cabling between the drive unit and the battery, which makes the system more reliable still. Inside the frame the battery is better protected against the weather and against theft. It is sold in a horizontal and a vertical version, in capacities of 400, 500 and 625Wh, and as the 750Wh Smart version described below.

The Bosch Powertube 400Wh and the 500Wh are the same length. The Bosch Powertube with 625Wh is a longer battery, and it does not fit every bike.

You can recognise this Bosch Powertube battery by the shape of the connector that serves as the battery's input and output. It runs in line with the width of the battery.

The Bosch PowerTube 750 is part of the Bosch Smart System. At 750Wh and 20.1Ah it holds more energy than any other single battery in the table above, and at about 4.4 kg it is also the heaviest.

Compatibility with the Bosch Smart System

The Bosch PowerTube 750 runs on the Bosch smart system, which is built around performance and connectivity. For your e-bike that means efficient energy management and synchronisation with your smartphone or other smart devices.

The vertical Bosch Powertube battery can also be recognised by the connector that serves as the battery's input and output. It faces the opposite way to the one on the horizontal battery.

Looking for a new or refurbished Bosch e-bike battery, or a cell replacement of the one you have? Have a look at our range of Bosch e-bike batteries.