Use PowerTube 500/600 in a 750 battery compartment with an adapter

Sometimes you don’t need the full capacity of a large battery with 750 watt-hours—especially for shorter urban rides. In such cases, a smaller and lighter battery can be a practical alternative. It reduces weight and makes handling your e-bike easier. But is this even possible with an e-bike equipped with the Bosch Smart System? The answer is yes, thanks to the Bosch PowerTube Adapter. In this tutorial you will discover how you can also use a 500 or 625 Wh battery on your e-bike with a 750 Wh battery using the PowerTube adapter.

1. Why is it advantageous to use a smaller battery?
2. Required materials
3. Approach

Initial situation:

• KTM Macina Kapoho with Bosch Smart System (Performance Line CX)
• Bosch PowerTube 750 battery

1. Why is it advantageous to use a smaller battery?

You might be wondering why you would opt for a smaller battery when more power seems like a better choice. Here are some compelling reasons:

• Weight Savings: A smaller battery is lighter, making it ideal for short urban commutes or daily trips where regular charging is possible.
• Cost Savings: Smaller batteries are often less expensive.
• Flexibility: Switch between different battery sizes depending on your needs—for example, a larger battery for extended tours and a smaller one for everyday rides.

2. Required Materials

• Bosch PowerTube Adapter
• Compatible battery (e.g., 500 Wh or 625 Wh)
• Screwdriver and other basic tools
• Bosch eBike Flow App (optional, for verification)

3. Approach

Start by removing the original battery from the downtube compartment. The KTM Macina Kapoho, like many other KTM e-bikes, features a specialized handle that makes removing the battery significantly easier. Next, unscrew the original battery mount and replace it with the KTM-specific PowerTube Adapter, which will later attach to the smaller replacement battery. To remove the proprietary mount, you’ll need a Torx T10 screwdriver.

Screw the adapter to the battery.

Extend the PowerTube 625Wh using the adapter

Now attach the adapter in place of the old mount. It must be securely fastened to the battery. The adapter adjusts the length of the 625 Wh battery to match that of the 750 Wh battery. Once the adapter is installed, attach the manufacturer-specific holder.
After the adapter is mounted, insert the battery into the downtube compartment. Finally, check that the battery is securely in place and that the system operates smoothly. The adapter matches the original battery mount and features the appropriate mounting slots.

The adapter matches the original battery mount and includes the mounting Slots.

Screw the adapter to the battery.

Testing

Switch on the ebike and ensure that everything works correctly. If the ebike system powers on and the Kiox 300 display lights up, the connection is properly established.
Note: With smaller batteries of 500 or 625 watt-hours, the range calculation and battery status display will automatically adjust accordingly.
Optional: Use the Bosch eBike Flow App to check the components and ensure the new battery is recognized.

Tips:

• Place the removed parts aside in the order you disassembled them. This way, you won’t get confused when reassembling them later.
• If you’re using a KTM adapter, it can be opened with a flap. Behind it, you’ll find a small compartment where you can store snacks or a multi-tool.

Products mentioned in the article

Pictures: Ebike24; Bosch eBike Systems