Bosch eBike system error codes (Purion, Intuvia, Kiox, Nyon, before the smart system) · Bosch Purion, Intuvia, Kiox, Nyon

Error 540 on Bosch Purion, Intuvia, Kiox, Nyon

What it means + how to fix it From the manual

Quick answer

Error 540 on the Bosch Purion, Intuvia, Kiox and Nyon (before the smart system) means “Temperature error.” Most likely cause: a long climb, a heavy load or hard riding. Try this first: switch off and let it cool.

Try this first

Free, and each takes under 5 minutes.

Switch off and let it cool
Use a lower assist level
Use an easier gear on climbs

Code meanings vary by brand. The same number can mean different things on different displays and controllers. Check your bike's manual to confirm.

About the Bosch Purion, Intuvia, Kiox and Nyon (before the smart system)

Bosch prints this same table in the Purion (BUI215) MY2023 US manual (pages English 12 to 14). source
The same table is in the Intuvia (BUI255) MY2021 US manual (pages English 15 to 17). source
The same table is in the Kiox Online Version (BUI330) MY2020 US/CA manual (pages English 35 to 38). source
The same table is in the Nyon Online Version (BUI350) MY2021 US manual (pages English 66 to 69). Bosch notes code 430 does not apply to the BUI350. source
These displays belong to Bosch's older eBike system, not the smart system. The Bosch smart system (for example the Purion 200 and Kiox 400C) uses six-character error numbers instead. source
Bosch also lists "7xx" for faults in third-party parts, and "Display is blank" for an internal fault of the on-board computer. They are not single codes, so they are not in this list. source

In plain English

The motor has reached its maximum safe temperature, and the system has cut power to protect it. After a long or hard ride, letting it cool is the fix. If it happens without much riding, something is wrong and a shop should check it.

Step-by-step checklist

Work from the top. Steps go from free and easy to shop jobs. Switch the bike off before touching any connector. Tick each step as you go. Your progress is saved on this device.

1Switch off and let it coolFree Turn the system off and give the motor time to cool down before riding again.
2Use a lower assist levelFree Drop to a lower assist level, especially on long climbs, so the motor and controller work less hard.
3Use an easier gear on climbsFree Shift to an easier gear before hills and pedal more. The motor works less hard and stays cooler.
4Check that the wheels spin freelyFree Lift each wheel and spin it by hand. Grinding, dragging or a rubbing brake makes the motor work harder.
5Have the motor testedShop job If the cable and connector look fine, a shop can test the motor's wiring and sensors. Opening a motor or working on its high-current wires is a shop job.

Parts you might need

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Only buy a part if the free steps didn't fix it. Always match the voltage and connector type to your bike.

Floor pump with gauge
Soft tires make the motor work harder and cost range.
View on Amazon

Still not fixed?

Pages to try next:

When it's time for a shop: if you've worked through every step and the problem is still there, take the bike to an e-bike shop. Bring your notes on when it happens, plus the code.

Words on this page: Controller