Bosch ebike motor refitting after overhaul

[Grimtim2020]

I've had an exchange motor back from the performance line bearings which i am sure is fine. However my cannondale moterra frame holes doesn't quite line up with the motor mount holes. I have tried to fit it today five time to no avail. I can get up to five bolts in but never six. Idont want attempt to load up the frame as it is a carbon fibre one. It appears bosch tolerances may be different from motor to motor. Has anybody else had these problems.

 

[Stihldog]

I always thought the motor mount brackets had a little play/movement. It can be a tight fit but eventually all 6 bolts go in…fairly easily. Maybe some bracket adjustment?

 

[Zimmerframe]

@Bearing Man any ideas ?

 

[B1rdie]

Double check that all the cables and wiring passing behind the motor are in place…
Undo some bolts an start setting this one first…
Driller ?!?!
Reifitting both the bosch on the cube and a shimano on the spectral demanded quite a lot of patience

 

[Hardtail]

I had the same issue. You need this tool to adjust the mounting brackets.
Wiha TORX PLUS® Security 25 IPR 1/4" bit for Bosch Gen.4 retaining plates

I bought a cheap set from amazon...

 

[Grimtim2020]

Thanks for the replies. I have a had a cup of tea, sworn quite a lot and with some patience it is in. In future the star drivers would be the way forward I think. Unfortunately I didn't have a tool to adjust them but it might speed up the process next time. Thanks for the pointer.

 

[Stihldog]

You’d think that a template or jig is needed sometimes to correctly pre-align the mounting brackets.

A Torx security driver is definitely needed to do this. But the motor must be out because there’s no access with the motor in place. At least that’s how I see it.

 

[Bearing Man]

@Bearing Man any ideas ?

We fit a lot of these motors in the workshop after they have been on the bench and have not had any problems so far? The brackets have virtually no movement around the TS25 screws so can never really be that far out. The one thing we do though, is start each TP40 bolt only a few threads into the frame and then once all bolts are started, then we tighten them. Always seems to work for us.

 

[2WheelsNot4]

Put in each of the bolts loosely and tighten slightly one at a time. Dont fit one, tighten, then the next and so on.

Edit- just noticed Bearing mans post

 

[2WheelsNot4]

One ofther thing. When doing the final tighten, dont do it 'round the clock' so to speak, but diagonally. So the one at the top, then the bottom, then the next top and so on and so forth.

 

[2WheelsNot4]

I've had a lot of experience in tightening my nuts.