Bosch DualBattery: Compatibility and Installation
Are you riding a relatively new ebike, i.e. built in 2014 or later, with a Bosch motor? Then you can almost certainly install a second battery. Bosch’s DualBattery system increases the range of the ebike up to twice. You can cover more kilometres without an unscheduled stop. Above all, you save the second battery in your backpack for charging.
Possible combinations with Bosch DualBattery
With DualBattery, a Y-cable splits the connection between motor and battery. In this way, both batteries are recognized by the energy management system and their capacity is combined. This now works with all current Bosch motors and batteries. Due to the numerous potential configurations, you have a lot of options. Depending on which batteries you combine with each other, you can achieve a total capacity of up to 1,250 Wh. You can choose from the Powerpacks with 400 and 500 Wh, as well as from the new Powertubes with 400, 500 and 625 Wh.
Does not fit every bike
Not every ebike is equipped with DualBattery right from the start. In addition, not every manufacturer offers a suitable kit for retrofitting it. However, the upgrade can also be quite easily installed by yourself. The biggest challenge is to properly attach the additional battery to the frame. This calls for a bit of creativity.
In theory, DualBattery works with all Bosch motors. In practice, however, the manufacturer of your ebike may have prevented this option for various reasons. This is not always the case, but it is possible. In most cases, the design of the frame simply does not offer enough space to integrate a second battery. Those who still want to try this out are thereby responsible, and in any case risk the warranty of the bike. Usually, a short message to the manufacturer is enough to find out what is feasible and what is not. Unfortunately, there is no list, database or similar, to help you safely clarify this by yourself.
The crucial question of space
If the signs are green, you can start. You will soon find out which spare parts and cables you need. First, you need to check one basic requirement: How much available space do you actually have.
Measure the available space in the frame of your ebike. There is usually space for the second battery on a frame tube, on the luggage rack or in the down tube. The last option is usually the ideal one. Depending on the type of bike, you will quickly find out how to best implement your project. E-cargo bikes usually offer several options. With a Fully E-MTB, or generally an ebike with a rather small frame size, there is a significantly higher risk of already giving up at this stage.
Dimensions of Bosch PowerTube: Bosch PowerTube 400 Wh: 360 x 84 x 65 mm Bosch PowerTube 500 Wh: 365 x 84 x 65 mm Bosch PowerTube 625 Wh: 428 x 84 x 65 mm
Dimensions of Bosch PowerPack: Bosch PowerPack 300/400/500 Wh Active and Performance: 325 x 92 x 82 mm
Dimensions of Bosch PowerRack: Bosch PowerRack 300/400 Wh Active and Performance rack: 372 x 76 x 122 mm
What you need to switch to Bosch DualBattery
Each ebike manufacturer is responsible for fitting and attaching the batteries to the bike’s frame or rack. Battery suppliers like Bosch merely provide their solutions. Therefore, there is no universal mounting for a second battery. With a bit of luck, the manufacturer of your ebike has a kit, a mounting plate or an adapter in its range of products. Today, some brands are already offering appropriate solutions, such as the Haibike MRS Range Extender or the Scott Range Booster.
If there is nothing readily suitable on the market, you can order all the necessary components individually. These include: brackets, screws, cables, lock cylinders and cover-caps. All these are common spare parts for ebikes with Bosch batteries. It’s the collection of all the things you need to upgrade to DualBattery. What and how much you need depends on the location of the additional battery. You have to budget about 100 Euro to 200 Euro for these accessories. We have already calculated this for you using two examples. In case 1, a second Bosch PowerTube 625 is needed, in case 2 a Bosch PowerPack 500:
How Long Do Bosch Electric Bike Batteries Last?
Battery-powered electric bikes have revolutionized inner-city travel by offering an alternative mode of travel that is less costly, more eco-friendly, and faster.
Bosch is one of the world’s leading giants and has contributed to fueling this global automobile revolution.
Electric bikes powered by Bosch battery packs usually have higher ranges, offer a smoother ride, and have relatively long lifespans.
How Long Do Bosch Electric Bike Batteries Last?
Bosch is a German company that has been part of the world of technology and engineering since 1884.
It started its battery designing and manufacturing segment in late 1922 and has since been one of the world’s leading and most well-recognized chemical battery producers.
Bosch chemical batteries are extremely popular in e-bikes and e-scooter for their unmatchable quality and longevity.
In general, a Bosch electric bike battery is expected to retain its quality and performance for over a decade, which usually accounts for 1500 to 2000 charging cycles.
To cater to the different kinds of electric bike preferences, Bosch designs and manufactures electric bike battery packs in various sizes, wattages, amperages, and capacities.
The higher a Bosch electric bike battery’s charge storing capacity, the more range and speed it will deliver. As a result, it will have a longer lifespan as it will not have to be charged as frequently.
Although the average lifespan of a Bosch electric bike battery is expected to be between 10 to 15 years, one can prolong or shorten it by how they ride their electric bike and treat the battery.
Continue reading to learn about what a Bosch electric bike battery is, how it works, and what makes Bosch better than most of its competitors.
over, the article will also bring attention to the top practices that can shorten a Bosch chemical battery’s life and highlight golden tips to care for one of these batteries.
What is a Bosch Electric Bike Battery?
Bosch electric batteries are chemical lithium-ion batteries designed to be low weight with an ergonomic design for easier handling.
Bosch has been designing lithium-ion batteries for many appliances and devices, and it started making electric bike batteries as soon as the industry gained popularity.
Today, Bosch is one of the biggest and highest-selling companies for electric bike and scooter batteries.
over, due to the lithium-ion composition, a Bosch electric bike battery can deliver high-quality performance and offer long-lasting durability.
As mentioned above, a Bosch electric bike battery comes with at least 1500 to 2000 charging cycles. This means that the Bosch battery can be fully depleted to 0% and fully recharged to 100% almost 1500 to 2000 times during its lifetime.
As a result, the Bosch electric bike battery can usually outlive the electric bike itself.
Although lithium-ion chemical batteries are notorious for being excessively sensitive to extreme internal and external changes, Bosch has successfully managed to counter this limitation through decades of battery-making expertise and intelligent engineering.
Furthermore, Bosch designs lithium-ion battery packs in various sizes and shapes.
Hence, different electric bike brands can outsource their batteries to Bosch and get the exact size and shape of the battery that will perfectly fit their electric bike’s unique frame.
Continue reading to understand how a Bosch battery works and what makes a Bosch electric bike battery better than all of its competitors.
How Does a Bosch Electric Bike Battery Work?
Bosch designs various electric bike batteries to meet the needs of different e-bike manufacturing companies and brands.
The most commonly found Bosch lithium-ion batteries used in electric bikes usually have 300-Wh, 400-Wh, or 500-Wh sizes.
This battery range allows both heavy and lightweight electric bikes to cover greater distances while traveling at high speeds.
This is how the mechanism of a Bosch electric bike battery works:
- When a person purchases an electric bike with a Bosch lithium-ion battery pack, they must first charge the battery to 100%.
- This allows electric charge to flow through the 40 round cells of a Bosch battery and get stored as chemical energy.
- When the rider begins to pedal their electric bike, the built-in motion sensors detect the rider’s pedaling motion and pass on the signals to the electric motor.
- On receiving the signals, the electric motor automatically turns on and begins discharging the Bosch electric battery of its stored chemical energy.
- The chemical energy is then converted to kinetic energy, with traces of heat energy as a byproduct.
- The newly produced kinetic energy is finally transported to the electric bike’s tires via the built-in energy transmitters; thus, the e-bike picks up speed and gains momentum.
Most electric bikes with Bosch battery packs also come with a regenerative braking system, which allows the excess heat energy to be converted back to chemical energy for further use.
This way, the Bosch battery’s charging level goes up as the rider hits the brakes of their electric bike.
The table below demonstrates how much power each Bosch electric bike battery can offer, along with highlighting its average charging duration.
| Battery Qualities | Bosch Lithium-Ion battery Pack | ||
| 300 Wh | 400 Wh | 500 Wh | |
| Mounting Type | Luggage or frame rack | Luggage or frame rack | Luggage or frame rack |
| Charge Storing Capacity | 8.2 Ah | 11.0 Ah | 13.4 Ah |
| Voltage | 36 Volts | 36 Volts | 36 Volts |
| Power/Energy Content | 300 Wattage | 400 Wattage | 500 Wattage |
| Standard Charging Duration (0% to 100%) | 2.5 hours | 3.5 hours | 4 hours |
| Fast Charging Duration (0% to 100%) | 2.5 hours | 2.5 hours | 3 hours |
What Makes Bosch Better than Other Competing Brands?
Almost a Century of Battery Making Expertise and Experience
Buying an electric bike with a Bosch battery pack gives consumers great relief and satisfaction because of the significance and reputation the name Bosch holds.
A Bosch electric bike battery comes with a century of battery-making expertise and experience that not many brands can claim to offer.
The company has had ample time to correct all operational and technical flaws to produce an electric bike battery that delivers unmatchable levels of durability, resilience, and range.
Bosch Electric Bike Batteries Are Long Lasting and Highly Durable
One of the most outstanding qualities of a Bosch electric bike battery is its high durability and long lifespan.
In general, most electric bike batteries can maintain their quality and performance for 5 to 7 years.
On the contrary, a Bosch battery retains its charge storing capacity and performance for almost 10 to 15 years.
Due to this extensive lifespan, the battery can usually outlive the electric bike and a rider can reinstall the same battery into a new electric bike.
over, due to the battery’s resilience and low sensitivity, an electric bike owner is saved from having to incur expensive battery repair and replacement costs.
Bosch Electric Bike Batteries Are Found in Different Shapes and Sizes
Most electric bike manufacturing companies prefer getting their chemical batteries manufactured by Bosch as they can get a battery made precisely the way they want.
Electric bike manufacturers can choose a frame battery, a rack battery, an integrated battery, or a dual battery.
over, Bosch batteries come in unique shapes, such as cylindrical or triangular, to fit into all kinds of electric bike frames.
Bosch’s Intelligent Battery Management System (BMS)
One key quality that separates a Bosch electric bike battery from its competitors is the Battery Management System (BMS).
Unlike regular lithium-ion batteries that can sustain a lot of damage by poor charging practices, the BMS of a Bosch battery allows the battery to detect any potential systematic errors to protect the battery cells from overloading.
Hence, an occasional mishandling or improper charging incident will not significantly impact a Bosch electric bike battery’s quality or lifespan.
Bosch’s DualBattery Packs
To offer an electric bike owner an unparalleled range to make intercity traveling possible, Bosch has designed DualBattery packs that include two high-wattage batteries integrated to perform as one.
This battery pack doubles the electric bike’s charge storing capacity, increases the e-bike’s top and average speeds, and allows the rider to cover longer distances without worrying about finding a power source to recharge the battery.
over, the Bosch DualBattery packs can drastically decrease a rider’s range anxiety.
As a result, more people have started preferring electric bikes over gasoline-powered personal cars or public transport for their everyday commuting.
Bosch Batteries Come with Long Warranties
Lastly, all Bosch electric bike batteries come with a one-to-three-year warranty, allowing e-bike owners to get free battery repairs if unexpected damage or error arises.
What Causes a Bosch Electric Bike Battery’s Average Lifespan to Drop?
Although a Bosch electric bike battery is one the most reliable, durable, and resilient chemical batteries on the market, there still are some limitations.
Improper battery charging and frequent mishandling can affect the Bosch battery pack’s performance and can decrease the battery’s average lifespan.
Some of the ways a rider damages and reduces a Bosch electric bike battery’s expected lifespan are as follows:
- By frequently riding the electric bike on a low battery charging.
- When the Bosch battery is forced to perform on a low charge, it permanently loses some of its charge storing capacity.
- When a person frequently charges their electric bike using an outsourced battery charger, the inadequate amount of electric charge can fry some of the battery’s cells.
- As a result, its capacity, range, and lifespan are reduced.
- If an overweight rider chooses an electric bike too small to carry their weight efficiently, the battery is pushed to perform beyond its healthy limit.
- As a result, the continued stress on the electric bike’s battery causes its range and lifespan to drop.
- Riders who constantly choose to ride their electric bikes at high speeds and hit the throttle eventually end up damaging the battery’s cells.
- Frequently and deliberately pushing the electric bike to go over arduous and sloped surfaces will overheat the battery, causing its lifespan to drop.
- over, a sharp rock can also puncture the battery, causing it to leak some battery fluid.
- If this happens, the rider has no choice but to incur expensive battery repair or replacement costs.
- Allowing the battery to deplete to 0% before plugging into a charging source is a highly discouraged practice.
- This way, the Bosch battery’s charging cycles get used up, and the overall lifespan drops.
Continue reading to learn how a person can prevent such damages to enjoy the Bosch battery pack for a long time.
Final Thoughts
Whenever people talk about electric bike batteries, Bosch is often the first and only name.
This is because the company has spent over a century developing a name that reflects reliability, durability, consumer satisfaction, and unmatchable technical expertise.
over, Bosch electric bike batteries can retain their quality and performance for more than a decade, which usually allows them to outlive the life of an electric bike.
However, poor practices and frequent mishandling can damage the integrated cells of a Bosch e-bike battery, causing it to lose its capacity and lifespan.
Hence, whenever you get a new electric bike powered by a Bosch battery pack, always read the instructions first, so you know exactly what practices you need to avoid to protect the battery against permanent damage.
You may like the following electric bike articles:
My name is Matthew, staying in Seattle, Washington. Electric Vehicles (Electric Cars Electric bikes) caught my attention for the last few years and my love for electric cars and bikes is everlasting. I spend many of my weekends traveling to various places all over various cities with my electric vehicle (e-bike and electric car). Here I am sharing my expertise, experience, and invaluable information about electric cars and electric bikes. Check out more.
How to Extend the Life of Your Bosch eBike Battery
New batteries are no longer that complicated, but here is a guide on how to extend the life of your eBike Battery focusing on the Bosch range of products.
The Basics
The 300Wh, 400Wh, 500Wh 625Wh PowerPacks used on Bosch-powered eBikes are amongst the most advanced batteries currently on the electric bike market. They offer a superior range, reliability longevity compared to many other batteries. However, this all comes at a price; with a replacement pack currently costing around £600. Some people are put off by the price of a replacement battery, thinking that it will have to be replaced every other year, but this is just not true.
Bosch actually guarantees their batteries for 2 years or 500 charge cycles (whichever comes first). This doesn’t mean your battery will pack up after 2 years and 1 day. In fact, Bosch themselves state that the battery should be good for around 10 years or 1500 full charge cycles. After 1500 cycles the battery will still work, but any battery will age over time so it will start to lose capacity and therefore not power your electric bike as far.
Also, it’s worth pointing out now that many people think that a part charge counts as a full charge cycle in Bosch’s terms. Unfortunately. it doesn’t! If you just top the battery up a small amount, only this is recorded and will not be counted until there are enough of these partial charges to count toward a full charge cycle.
As a registered Bosh eBike dealer, when a Bosch-powered eBike visits our workshop we can use our diagnostics tool to read the battery itself. The Bosch battery is a very clever unit and records many different parameters, these are then saved within the system for us to analyse and consider depending on any issues presented. Also, we can tap into the system and see exactly how many ‘Full Charge Cycles’ this particular battery has had. Furthermore, we can view many other variables within the Bosch software, for example – maximum/minimum battery temperature, charge state, usage, etc.
Here are some of the most common questions we hear regarding Bosch batteries:
If your eBike came from us, we normally charge the battery fully just before letting it out of the workshop as we know you’ll be itching to ride it the minute you receive it. This helps condition the battery and gives it a starting point from which to gauge the rest of its operation. If you find it’s not fully charged, please charge it to 100% before riding. This applies to all brands of electric bike batteries too.
How often should you charge your Bosch eBike battery?
The new Lithium cells used within the Bosch battery packs are very advanced. Unlike the older style batteries where you had to completely discharge the battery and then fully charge it back up again, the new Bosch PowerPacks do not need this. In fact, it’s much better to just top up the battery after every trip. So if you have just cycled 10 miles on your electric bike, it’s better to top it back up to full when you get home rather than incorporating a few trips before charging fully.
Can I still clean my bike?
Yes, as with any bike – it is good to keep all components of your eBike thoroughly clean. If the exterior case or shell of the battery and motor is dirty, which will happen, this does not affect the performance of the internals. The best way to clean the battery is with a specialist bike cleaner, wet sponge (or soft paintbrush!), and low-pressure hose. A typical garden hose is perfect for washing away grime without applying too much pressure, once the area has been lightly agitated with the bike cleaner and sponge/paintbrush.
Although the Bosch batteries are weatherproof, it is never advised to use any sort of high-pressure jet/pressure washer on your bike. This pressure can force water into the battery case itself and potentially cause damage. It can also force water into other parts of your electric bike where you don’t want water to be (motor, bearing internals, suspension seals, etc.). So although it may be quicker to clean please don’t use pressure washers at all.
Will my battery range be affected if using an inverter from my vehicle or motor home?
No, you can use inverters to charge your electric bike – for example – from the cigarette lighter port in most cars. This can be handy if you are out and about or wish to charge on the move. But please make sure that the inverter itself is rated for the correct output for the Bosch charger. You can normally find this information on the inverter’s packaging or on a sticker on the inverter itself. The Bosch charger is designed for a rated voltage between 207 – 264 volts with an output of 42v.
The charger only charges the battery at a low 4 amp current; this is fine for most inverters and car batteries. Please check these values to make sure the inverter is compatible before plugging it in. One point to remember is that depending on the inverter itself, the battery may take a little longer to charge than if it was plugged into the mains.
Most importantly of all make sure the vehicle engine is running whilst the battery is on charge because it could drain your vehicle battery faster than you think.
How you can extend the life of your eBike battery easily:
In very simple terms, the harder you use your eBike the faster the battery will discharge. You can maybe classify this as the trade-off between fun and economy! Remember, the power of the motor can peak at 500w (depending on the specific Bosch motor) so it can draw power from the battery quicker and put a higher load on it the harder you push, and the assistance required.
The faster it discharges, then the more you will be charging it back up. This means that you could end up performing many more charge cycles than someone who is using their eBike lightly in the same time period. After a long period of time, the capacity of the battery will gradually drop. You could, therefore, be in the position of replacing it sooner if you’re riding your eBike close to capacity for the majority of the time (this is especially prevalent in de-restricted bikes).
We would recommend using an assistance level that works for you. Quite honestly you don’t ‘need’ to use the eBike flat out in ‘Turbo’ all of the time (even though it is fun!). The use of ‘Eco’ ‘Tour’ modes for the majority of riding is generally more than enough, with ‘Turbo’ mode assisting on the very toughest of climbs or in tough conditions.
You can also utilise the eMTB mode on your Bosch system, which will vary the motor’s input depending on what you are putting in yourself. eMTB mode is always optimally adapted to you, the incline, and the terrain – regardless of rocks, roots, or steps. This will give you the most bike-like ride feel and will give you an even drain on your battery.
Obviously, everyone’s fitness levels are different so you will need to work out what works for you, it is far too easy to hit ‘Turbo’ mode for the majority of your ride. The bike won’t go any faster (mph) but it will have more ‘grunt’, in fact, the eBike will only go as fast as you pedal, it’s just the amount of assistance the motor gives you that changes.
I’m putting my eBike away for the winter, will this damage the battery at all?
No, we know that some riders may not want to cycle through the cold, wet, and grim UK conditions found in the winter. You can store your bike away, it’s not a problem, however, there are some steps you can take to keep your battery healthy during these times.
If you are keeping your eBike outside in a shed or garage, then it’s always best to bring your battery indoors. The Bosch batteries are capable of being stored in temperatures between.10 through to 60 degrees centigrade. But the cells don’t like to be stored in very low or very high temperatures. In fact, the best possible temperature for storage is room temperature – around 15-20 degrees.
Once in the house at room temperature, store the battery in a dry and secure place. Sticking it on a shelf in the kitchen above the kettle runs the risk of moisture traveling up from the kettle and into the battery case. So we probably wouldn’t recommend this as a location for storage! The perfect place is tucked away in a cupboard where it’s kept at optimum temperature, away from moisture, and where it’s not vulnerable to being knocked at all. We know it can make a very good doorstop, it’s tempting; but not good for your battery. Just make sure you remember where you left it when you come to want to ride it again…
Storage
When storing your eBike battery for long periods of time it’s best to keep the battery partially charged. If you store the battery completely flat then you run the risk of damaging the internals of the cells themselves. Also if you store the battery fully charged this can leave the cells under more pressure. So it’s best to keep the battery stored in between.
For the Bosch battery in particular the optimum charge state to leave it in is 60% (Or 3 LED’s lit on the battery level indicator). Try to check the capacity every 6 months or so. When the battery reaches 1 LED showing, then top it back up to 3 LED’s again. Many people think it’s best to keep the battery on charge so it’s always topped up in storage, but this is simply not the case. The Bosch charger won’t ‘overcharge’ the battery at all and does not trickle charge.
Will it harm the battery if I run it completely flat on a ride?
No – it’s never recommended to run the battery completely flat – but for longer rides, we know it can happen. The Bosch Battery is protected by its onboard BMS (Battery Management System). This means it’s protected for deep discharging, the BMS won’t allow the battery to run completely flat.
It may seem that you have no power left, but the BMS will have already shut off the power to the motor before it can hurt itself. We all know that the beauty of the Bosch drive is you can still ride without any resistance with the power switched off. On a side note here, if you are running lights directly powered from the Bosch motor and you do run out of power, the BMS will allow a small amount of power still to the lights so you will still remain visible!
I ride in very cold conditions during the winter, will this affect my battery life and performance?
The simple answer is yes. Similar to fuel MPG in a traditional car, Bosch says economy can be affected up to 30% in sub-zero conditions. So if you are consistently riding in these conditions it can really affect not just your range but will decrease the overall lifespan of the battery as well. There are certain actions you can take to prevent this, such as wrapping an external Bosch powerpack in a specific neoprene sleeve to keep it as temperature as possible.
Should I remove the battery when transporting my bike on the bike rack of my car/motor home?
Yes, this is strongly advised, put it in a dry safe place inside the vehicle. It is less likely to get knocked and lessens the chances of the battery flying off the bike on the motorway if it’s not secured properly.
The best place to store the battery is under the driver’s seat, this means it’s out of the way and also shouldn’t move around too much. Wrap it in a towel to prevent any knocks. Do not leave the battery on your parcel shelf, if you end up braking hard, the 2kg battery is the last thing you want hitting you in the back of the head.
Also, by storing it in the car it keeps the battery from getting wet. Although the battery is rainproof, people don’t realize that if you’re traveling at 70mph down the motorway, the water air traveling over your car is then doubled in speed as it wraps around the back of your vehicle. This means the battery could be being sprayed with water at around 140mph! This is stronger than a pressure washer and can force water into the battery and components of the bike itself.
I dropped my Bosch battery and the case is cracked, what shall I do?
If your Bosch battery (or any eBike battery for that matter) is damaged in any way, then it should be looked into being replaced. Even if it seems OK on the outside one or several of the cells inside may be damaged, this can then move on to other cells and the whole pack can become a ticking time bomb. The battery could seem fine and work but weeks later the effects of the damage could become apparent. The battery could heat up or even ignite in extreme circumstances.
Do not under any circumstances ship this battery anywhere. A faulty Lithium cell can reach temperatures of 1000 degrees. It’s really not worth the risk, visit us in-store and have it replaced.
So, how many miles can I ride on a Full Charge?!
Well this is the million dollar question we get asked over and over again. And to put it frankly, there is no one fits all answer to this question! You see, there are multiple factors at play which affect the distance capable on an eBike.
Tyre pressures, total system weight, type of bicycle, tyre tread, battery capacity, motor system, cadence, environmental conditions, riding mode, average riding speed and even road surface choice will have individual and then combined factors on what you can get out of your Bosch motor battery.
Bosch have a fantastic tool on their website, classified as Range Assist which can help you calculate the range for your next eike ride or tour. This takes into account all of the above factors, for you to determine by the sliding tools, and it will calculate the estimated range for you! Bosch Range Assistant – Here
When was your eBike last serviced?
Something as simple as a brake pad rubbing can slow you down considerably. With the extra assistance on an electric bike, you may not even notice the extra drag. But the motor will be working much harder to assist you and therefore will drain the battery faster. It’s best to get your eBike serviced at least once a year to keep it in good shape which can pay dividends to battery health.
I think my battery needs replacing, what shall I do?
You should visit a Bosch dealer and have the battery capacity checked properly. We won’t take a meter near it, we will plug the entire bike into our computers and be able to give you a decision straight away if the battery needs to be replaced. On request, we can also print diagnostics reports for your records. When a new battery is purchased it comes with a new Warranty from a Bosch dealer, so be sure to keep the receipt of the purchase date safe.
Remember if you treat your Bosch eBike Battery well, it will treat you well in return. We hope that this guide will help you to extend the life of your eBike Battery!
Visit our specialist page for everything you could possibly want to know about eBikes and how they can help you.
Why not also take a look through our eBike options?
Replacement Electric Bike Batteries Guide
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A good e-bike battery should last for hundreds of cycles. With average use, this means several years. Eventually, electric bike batteries need to be replaced as their life cycle comes to an end.
You can tell when a battery is nearing the end of its life when it does not provide you with much range. Some high-quality batteries that come on the top e-bikes such as a Bosch battery have a battery management system (BMS) integrated into the battery that actually tells you the current capacity and also how many charge cycles it has gone through.
But no matter what type of battery you have you’ll sooner or later be asking yourself the all-important question: how can I replace my e-bike battery?
Down below Electric Bike Report dives into this question and more in greater detail.
Are E-bike Batteries Interchangeable?
In general, the answer is no – you should only replace a battery with one that comes from the same manufacturer and is of exactly the same spec.
The reason is that the original e-bike or kit manufacturer has the responsibility to ensure that the battery pack, charger, and e-bike all work safely together, and using a ‘non-original’ replacement pack potentially introduces all sorts of uncontrolled risks.
It’s a little more complicated than this in some situations. For example, some Bosch batteries of different capacities are explicitly made to be interchangeable and there will be many instances where an original supplier and/or manufacturer of the e-bike cannot be traced or has gone out of business – in such cases we look at your options below.
As an important side note: you should always, if possible, use a charger that comes from the original manufacturer too. The one that comes with your battery should sync up well and not overload the battery. Pairing your battery with a different charger adds in risk of malfunction during charging.
Let’s first look at the basics of getting a replacement battery for your e-bike, then we will look at some of the major manufacturers of e-bike batteries and some of the main e-bike manufacturers to see which common battery types are still replaceable. Let’s consider the options for replacement in terms of desirability.
Where Should I Go to Get a Replacement E-Bike Battery?
On this last point it may help to note that there are a couple of manufacturing standards for rechargeable lithium-ion batteries used in e-bikes. Although it’s not a legal requirement, it may be that one of the standards is actually marked on the battery itself.
The standards are BS EN 50604‑1 and UN38.3, the latter required for lithium-ion battery transport by air, sea or land. Just because these standards are not marked on a battery doesn’t mean it does not comply with them – but it is a reassuring sign if a battery does bear one or both of these marks.
Note that using a replacement battery that does not come from the original manufacturer (whether a dealer is involved or not) may void the warranty of your electric bike or kit. Check with the e-bike or kit company to understand what their policy is regarding the use of aftermarket replacement batteries.
Replacement Batteries from Original Manufacturers
Bosch E-Bike Batteries
Only Bosch manufactured batteries will be used on any new Bosch e-bike – this has always been the case and so it makes advice on interchangeability a little more straightforward than with the likes of Shimano and Brose who have both allowed the use of third party batteries with their mid-drive motor systems.
There have been four basic designs made by Bosch over the years (good online overview here):
- Rack mounted batteries: PowerPack in 300, 400, and 500 Wh versions which are all interchangeable with each other.
- Down tube mounted batteries: PowerPack in 300, 400, and 500 Wh versions, current versions of which are all interchangeable with each other.
- Frame integrated batteries: PowerTubes in 400, 500, and 625Wh versions, with the 400 and 500 units being interchangeable with each other. The 625Wh may be retrofittable but it needs a compatible frame with a big enough space to house it (400 and 500 units are the same physical dimensions but 625 is bigger). 500 and 625 Wh units are used on the Dual Battery system to give a capacity up to 1250Wh.
- Frame Integrated ‘Smart’ Option batteries: This is a new 750Wh option for 2022 and will be only compatible with 2022 e-bikes that feature the Bosch ‘Smart’ system and will not be compatible with other Bosch e-bikes that are ‘non-Smart’. Similarly, other types of PowerTube batteries (400, 500, and 625Wh versions) will not be compatible with e-bikes featuring Bosch’s ‘Smart’ system.
Some third-party batteries compatible with Bosch systems are available as detailed in the section below.
There are some suppliers of batteries that will fit older models, in some cases dating back to 2011 when the Bosch e-bikes first entered the market, for example, The Holland Bike Shop in Europe sells some batteries compatible with much older Bosch-powered models.
Shimano E-Bike Batteries
Shimano produces its own brand batteries for use on their systems, but you may also find new e-bikes powered by Shimano motor systems with batteries manufactured by their licensed partners Darfon and SMP. These third party batteries are not interchangeable with any Shimano batteries.
Shimano’s current range includes rack-mounted, downtube-mounted and frame-integrated batteries from 418Wh to 630Wh. You can see a brief overview with detailed links to each battery on offer here.
It’s important to note that each battery model has a limited number of specific battery mounts it will work with, so it is important to replace an old battery with one that is compatible with the mount on your e-bike. You can check out detailed compatibility info here and here.
Shimano says that ‘the oldest current battery we have is the BT-E6000 and the corresponding battery mount BM-E6000. These are compatible with all five of our current drive units (DU-EP8/E8000/E7000/E6100/E5000), but not earlier systems. For reference, DU-E8000 is the oldest in that list – it was introduced in 2016.’
Brose E-Bike Batteries
The only battery listed on Brose’s own website is a 630Wh frame-integrated option.
However, Brose systems are widely used by other manufacturers who also spec own-brand or third-party batteries. These include the likes of the widely respected battery manufacturer BMZ and well-known brands like Scott and BULLS.
For example, Specialized’s ‘full power’ range use Brose-based mid drives and a range of their own brand frame-integrated batteries. Although information on interchangeability is scarce, a Specialized FAQ page, in response to the question ‘Can I increase range by using the 604Wh aftermarket battery in any Turbo Vado/Como?’ says yes, all Vado batteries are cross-compatible as long as you are running the latest firmware (by implication so are Como and Turbo full power batteries are cross-compatible too).
The above appears only to address compatibility on current Specialized models and battery availability for older models appears a bit more complex with lots of debate online over the matter.
The fact that the latest Specialized e-bike batteries contain a Bluetooth chip to communicate with the latest Mission Control App certainly suggest both backward compatibility and availability of third party batteries will be very limited. Current e-bike batteries available from Specialized can be found here.
Yamaha E-Bike Batteries
Yamaha has integrated, rack-mounted and frame-mounted options ranging between 400Wh and 600Wh but information on backward compatibility is rather hard to find. Their systems appear on Haibike models and in the US on their own brand models too.
Giant use Yamaha motor systems but apparently have their own brand of battery – the EnergyPak range. The standard EnergyPak comes in rack-mounted and frame-integrated options whilst the Smart Compact variant allows for faster charging.
Finally, there is the Giant EnergyPak Plus, for use with the Smart Compact – a range extender style battery that fits onto the frame and effectively increases the capacity of the main Plus battery.
Giant’s Service web page states that there are EnergyPaks with 300, 360, 400, 500 and 625Wh capacities and also states ‘Giant EnergyPaks are interchangeable’.
Fazua E-Bike Batteries
This lightweight German-made system uses a frame-integrated 250Wh design and there have been two types of battery, Battery 250 and Battery 250X, the latter having the ability to be switched on and off remotely.
The latest Fazua Evation 250X battery is compatible with all Fazua electric bikes from 2019-22.
GRIN and Cytronex E-bike Kit Batteries
Canada’s GRIN is a true expert in producing a wide variety of e-bike kits. Whilst they do several designs of batteries, one of their best options from a replaceability point of view is their own brand LiGo batteries.
LiGo batteries are very unusual in being modular so that you can easily connect together as many as you like to increase or decrease battery capacity at will. They are particularly suitable for lightweight and folding bikes (I use them on a GRIN Brompton kit) and also for those who want to air travel with e-bikes as the individual battery units are only 98Wh and so are generally allowed on passenger aircraft (disconnect them from each other for travel and reconnect them on landing to make a useful e-bike battery).
The design has been around for several years and is backward compatible.
The UK’s Cytronex produces both European and US spec lightweight kits which use a unique own-design of ‘bottle battery’.
Cytronex says all their lithium bottles are compatible forwards and backward from the first version in 2017. They have different firmware for the new Bluetooth variant but both this and the non-Bluetooth version allow you to use the new 2-way – 5 level Boost Button or the previous one-way 3 level button.
In fact, if you have old and new kits on two bikes you can switch the bottle between both and it will recognize the two different button types automatically.
E-bike Manufacturers Own Brand Batteries
There are hundreds of e-bike manufacturers in the more budget space so it’s way beyond the scope of this guide to cover the options for each one; rather we’ll take a look at a couple of the market leaders.
Rad Power Bikes E-Bike Batteries
Rad Power Bikes first started producing e-bikes for the North American market in 2015 and now claims to be the US market leader. Their website lists several replacement batteries and their current lineup of bikes uses one of two battery designs.
There is the External Battery Pack (with the option for the smaller pack specific to the RadMission) which is compatible with all 2018 and newer model ebikes except the RadRover 6 Plus and RadCity 5 Plus, which use the Semi-Integrated Battery Pack.
Rad Power Bikes does offer legacy options for bikes older than that 2018 ‘cutoff’ and although some of these legacy batteries are currently out of stock Rad says they have plans to restock them.
The battery packs are consistent across their main sales areas of Canada, US and Europe.
The Rad Power website has a great filter system so you can track down the compatibility of what batteries are in stock against all current and previous models, right back to the original 2015 RadRover. All e-bike manufacturers’ websites should provide this service!
Pedego E-Bike Batteries
A longstanding US manufacturer with a clear set of battery specs for current models here. However, there doesn’t appear to be any info about legacy batteries or backward compatibility.
Interestingly, and it seems uniquely amongst the mainstream manufacturers, Pedego have recently introduced a serviceable battery (pictured above) – designed to be easily maintained at the local Pedego store. It features a rear light, brake light and indicators to boot.
Batteries for Out-Dated Motor Systems
There are a number of older motor and battery systems that are either not used or little used these days but there are still some suppliers out there who may be able to help out and if you are in this position a bit of internet research might just turn something up. Let’s take a look at a couple of examples.
BionX E-Bike Batteries
BionX operated between 1998 and 2018 and were once one of the leading e-bike system manufacturers in North America, with the likes of Trek and Kalkhoff using their systems.
There are still limited stocks of spare parts available here and there, including batteries, for example on this Ohm webpage.
Heinzmann E-Bike Batteries
German company Heinzmann had a great reputation for quality and produced the now obsolete Classic system and the newer Direct Power system. At various times both were available as kits or fitted to off-the-peg e-bikes.
In the UK Electric Vehicle Solutions are the main stockist of complete Direct Power kits and of spare parts for the Classic system.
What About Non-removable Frame Integrated Batteries?
A relatively small number of e-bike batteries are incorporated into the frame and not designed to be removed by the rider – they must be charged on the bike. Whilst perhaps inconvenient for some, the system has the benefit of a sleeker and simpler design and keeps the battery cells well-protected.
The Ebikemotion X35 system is one example of the most common lightweight systems out there to feature a frame-enclosed battery.
When it comes to replacing these batteries, to be clear, our official advice is that this is a job for the dealer, or expert shops to do only.
DIY in this area can get tricky in a hurry. Looking into service options to replace batteries in an integrated system is something to consider before purchasing the bike.
Third-Party Replacement E-Bike Batteries
For some older batteries – or even some current ones – there may be manufacturers other than the so-called OEMs (original equipment manufacturers) who made the original batteries. These third-party companies are not recognized by the original e-bike manufacturers so if possible it is always best to go back to your dealer or the manufacturer directly to source an original battery.
However, third-party batteries may be a solution where no original batteries appear to be available.
There are a growing number of companies that provide third-party batteries and here we take a look at a couple of the bigger operations.
Please note that on e-bikes that are still in their warranty period, replacing the battery with one from a third-party manufacturer will most likely void the warranty.
FTH Power has a good amount of experience in the electronics business and has diagnostics and assembly capabilities. They look to have good stocks of popular far eastern battery brands such as Reention (used by the likes of Juiced and Surface 604) and Hailong. They also have this handy battery/model finder to see if they have batteries for your particular model of e-bike.
Third-party battery provision (and recelling services) appear to be bigger business in mainland northern Europe than in the U.S. It makes sense, this is where e-bikes have been around much longer and where the average value of e-bikes is higher. The need to keep older bikes going longer is greater. For example, Heskon is a major supplier of replacement batteries to dealers and Fiets Accu Revisie is the part of Heskon that sells direct to customers.
The UK’s Electric Transport Shop network offers battery diagnosis (refundable against a replacement battery or recell if required). The ETS says they also have stocks of Battery Management System chips that can be used on certain packs, usually on older e-bikes.
The ETS also says ‘There are so many shapes of e-bike batteries now that we cannot guarantee that we have cell packs to fit them all and it is usually cheaper to buy a factory-built replacement than to hand-build a replacement pack in the UK so we usually recommend buying a battery from the original supplier if the diagnosis proves that’s what is needed. If their supplier is no longer available to supply a replacement pack in this instance we will help people find a suitable replacement or as a last resort we will offer to wire in an alternative pack which may be in a different position on the bike.’
What Should I Do With My Old E-bike Battery?
If at all possible the ideal solution is to take it back to the dealer you bought it from who will send it on for recycling.
In the US the industry is in the midst of setting up its own recycling scheme. It was organized by People for Bikes and will be directly coordinated under the auspices of Call2Recycle. There will be a network of battery drop-off locations from the nation’s roughly 3,000 independent bike shops. Manufacturers and retailers can sign up here.
The batteries will be sent on to ‘processing partners’, four of which are domestic and two of which are foreign—one in South Korea and one in Belgium.
The consortium brands are funding the recycling service, which will be free to riders; of course, consumers will still have to pay for replacement batteries. There are also plans for a consumer-direct mail-in recycling option in the summer – EBR will keep you posted on its development.
There are already such ready-made recycling networks in mainland Europe and the UK is just beginning to establish such a network.
This guide to replacement electric bike batteries hopefully covered the basics of what is out there for you. It’s certainly just the tip of the iceberg though. If there is anything else that wasn’t covered here, let us know in the Комментарии и мнения владельцев below and we’ll update this guide with the info our readers are looking for!