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The Bosch electric bike motor is widely regarded as one of the best in the industry. From its inception way back in 2010 it has evolved into one of the most reliable and cutting-edge e-bike systems currently available.
Halfords’ in-house Carrera brand of electric bikes has been around for a few years now, and the Carrera Crossfuse is the first e-bike in the range to be fitted with the excellent Bosch Active Line Plus motor. The motor is great, but how does the rest of the bike stand up to closer scrutiny? Read my review for more information.
Summary
The Carrera Crossfire has always been one of Halford’s best-selling bicycles. When they first released the Crossfire E electric bike a couple of years back it was an instant hit with consumers.
For those of you unfamiliar with the Crossfire E, it uses a dependable, but somewhat dated rear hub motor. As the years have gone by, consumers are now demanding e-bikes that are lighter and have the latest high-tech components fitted.
The Carrera Crossfuse was released in response to this increased demand for cutting-edge e-bike technology.
Let’s have a closer look under the surface of the Crossfuse to see what makes it tick!
Electric Components
Bosch Active Line Motor
Bosch is now synonymous with the electric bike industry. They have become a global leader in e-bike drive systems, and are at the forefront of research and innovation.
The Bosch e-bike motor division was founded in 2009, and its first motor was unveiled in 2010. Since then, they have set the bar, for all other electric bike motor manufacturers.
Halfords have thought this through, as the Bosch e-bike motor now carries with it certain kudos amongst savvy consumers.
The particular motor fitted to the Carrera Crossfuse is the Bosch Active Line Plus motor. This motor has been specifically designed with the more leisurely rider in mind. Bosch also makes higher-performance motors for mountain bikers and road cyclists.
What can I say about this motor based on my own experience with it? Well, it’s certainly not designed to have the high torque output of the CX Line motor. When you ride an e-bike with the Active Line Plus motor fitted, the experience is sublime. It is very quiet, very smooth and the pedal assist is so incredibly sensitive, that you do feel like you have cybernetic implants in your legs!
This motor is not designed to be ridden hard off-road. The torque output of 50Nm is modest for a mid-drive motor, but in fairness, this motor is designed that way. This also means the motor is very efficient, with the 400Wh (watt hour) battery giving a potential range of 80 miles.
Another great thing about the Carrera Crossfuse is that it weighs a good 2-3kg lighter than its Crossfire E sibling.
One other thing worth mentioning is when the motor cuts out at 15mph, there is no noticeable increase in pedalling resistance, the only thing you may notice is the extra weight of the motor and battery. Pedalling this bike on the flat with the assist switched off is just like pedalling a heavier regular bike.
Display
The Bosch Purion display is compact and functional. It is very neat and doesn’t look out of place on the handlebar. You can adjust the level of pedal assist using the plus and minus keys. Speed and battery power are also displayed, and there is a trip function.
There is also a micro-USB port on the display so the dealer can diagnose any faults if they occur.
Battery
The Bosch PowerPack 400 battery is compact and lightweight. The PowerPack 400 uses the latest high-energy-density lithium cells, which guarantee battery longevity and performance. This battery also uses a smart BMS (battery management system) which monitors important things like temperature fluctuations, voltage and current.
If the smart BMS picks up any anomalies, it temporarily decommissions the battery until an approved Bosch technician can diagnose the fault. This is a very good feature to have on any e-bike battery as it limits the potential for long-term damage.
As far as battery range is concerned, the Carrera Crossfuse should be good for a maximum range of approximately 80 miles, but in real-world riding conditions, this figure will vary greatly, depending on the weight of the rider and how much assist is used. I would say a realistic range is probably in the 40-60 miles region. You can use Bosch’s excellent Battery range calculator to get a rough idea of the range you can expect based on various metrics.
Bike Components
Gearing
Dependable Shimano components are used for the gearing. The Alivio rear derailleur is commonly found on mountain bikes and has a long cage to cope with the wide range 11-34 9-speed cassette. The gear shifter is an Acera 9-speed trigger shifter making for smooth reliable gear changes.
The front crankset uses a single 42t chainring, making the gearing of this bike more than suitable for riding on city streets or in the hilly countryside. The whole package is finished off with a Shimano e-bike-specific chain.
Brakes
The Shimano M315 hydraulic disc brakes provided assured stopping power. Although these brakes are at the cheaper end of the scale, they are perfectly suited to a hybrid bike like the Carrera Crossfuse.
Front Suspension
Suntour NEX HLO front suspension with 63mm of travel is nothing out of the ordinary for an electric hybrid bike. These forks have a hydraulic lock-out and can also be adjusted for damping.
I have ridden many hybrid bikes with these suspension forks and they are perfect for soaking up smaller potholes and coping with things like small tree roots and gravel when ridden off-road.
As long as you don’t expect these forks to cope with anything too demanding, they will do the job perfectly.
Wheels and Tyres
Both front and rear rims are double-walled alloys with good quality Shimano sealed hubs. The tyres used are the excellent Schwalbe Tyrago KG 700 x 40c, which not only have a good level of puncture protection but are versatile enough to be used on and off the road.
Finishing Kit
The alloy finishing kit looks nice on this bike and it is set off nicely against the matt metallic grey paintwork. The saddle is a good quality Selle Italia Gel saddle and should be comfortable enough for most people.
Frame
This frame has typical relaxed hybrid bike geometry and is specially made for the integration of the Bosch motor. It provides a nice upright riding position.
It has internal routing for the brake pipes and electric cables, and the rear gear cable is routed underneath the top tube.
All in all, it looks nice and has a good quality finish to it.
Who is the Carrera Crossfuse aimed at?
I would say the Carrera Crossfuse is aimed at anyone from weekend leisure riders to commuters and people who just want to get back into cycling.
There are the usual provisions for mudguards, pannier racks and so on. Because of the efficiency of the motor, and the laid-back riding position you could also load it up with panniers and do a spot of touring on it.
Conclusion
I think the Crossfuse is an excellent addition to the Carrera range, all Halfords have to do now is a Carrera mid-drive mountain bike, as currently, all their e-MTBs use Suntour hub motors.
Is the Carrera Crossfuse good value for money? With most of the big brand competitors raising their prices (in 2021) the Crossfuse is now one of the cheapest Bosch-powered e-bikes available and represents excellent value for money.
The Carrera Crossfuse is a good hybrid electric bike and a joy to ride, the electric assist is just sublime and it has the back-up of Halfords nationwide network of stores.
The bike comes with the usual 2-year warranty on electrical components and a 1-year warranty on all other components.
Customer reviews for the Crossfuse are generally very favourable, and having ridden it, I think it is a pretty decent bike!
Buy the Carrera Crossfuse online at Halfords
If you own a Carrera Crossfuse, please feel free to share your experiences in the comments section below.
I have owned a Crossfuse for 3 years and 3000 miles, the on going issue with bettery/power failure is driving me mad. Nobody in the local Hafords branch seem to have a clue.
I can’t even sell it as it is so unreliable. Ordered a Cube now so the Crossfuse is destined for the scapheap
Hi Tony. I really enjoyed reading your in depth review of the Crossfuse. I’ve owned a Crossfuse for nearly 3 years now. I love the bike, and have put about 4000 (mainly summer) miles on it. One thing I did notice in your review, was that you said it uses the Active Line (40Nm) motor: in fact, it uses the more powerful (50Nm) Active Line Plus unit. This is a far better motor than the standard Active Line, as it provides 20% more torque, and it was the one of the main reasons I chose to buy the Crossfuse. It’s unfortunate that Halfords own description of the bike says it uses the Active Line motor(!), but if you look in the ‘specifications’ section, next to ‘bottom bracket’ it does say Active Line Plus there. Externally, the ‘Gen 3’ Active Line and Active Line Plus motors look identical, except for the wording on the left hand motor cover. It’s possible that Halfords have started using the lower power motor since I made my purchase, but I don’t think they have. You may be able to ask them for confirmation? I just thought I’d mention that, as there’s a huge difference in performance between the two. Anyway, thanks again for the excellent review!
Hi Dave,
Thanks for bringing this to my attention. I’ve just checked with Halfords and it does still use the Active Line Plus motor so I’ll update the article accordingly.
All the best,
Tony
would you recommend these for towing a child trailer ?
I haven’t tested the Carrera Crossfuse with a child trailer, but I don’t see any problems. The Bosch motor should be powerful enough to cope with the extra weight.
Hi I would like to purchase a cross fuse e bike for £1699.00 but when you go to the link it goes up to £1899.00 why is that?
I was in a halford store today in Southampton looking at this bike they never mentioned a £200 off price it was £1899.00 ?
Confused? Yes I am !
Hi,
Halfords are constantly changing their prices, they tend to change prices regularly. When I reviewed the Crossfuse it was £1699 which I thought was a fair price. At £1899 it’s looking less competitive in the face of the competition. Thanks for letting me know, I’ll update the price on the article.
Regards,
Tony
The weight in the sales pitch states it is 23.9 kg approximately but doesn’t say if this includes the weight of the battery or not? I need this battery-less weight for working out which Thule bike carrier to get and which would be suitable for my wife’s Toyota Yaris Hybrid?
Hi James,
The 23.9kg does include the weight of the battery – The battery weighs approximately 3kg so the battery-less weight should come in at just under 21kg.
Regards,
Tony
We’ve just bought Crossfuse eBikes. Love them so far. ONe question does anyone have a Bike Stand fitted. If so which one have you got , supplier, how easy is it to fit. Thanks
Yes, Halfords supplied and fitted ours but they are not ideal as they cannot be adjusted to be at a best angle for keeping the bike upright and ours can easily fall over at a slight touch or in strong wind.
What a tool. I have ridden a bike since the year dot. In the past couple of years due to being older than Gods dog and bits of the body wearing out decided to enlist a little help. It as given me renewed lust for cycling, back out in the country lanes up hills no sweat. Whiz’s along at 10-15 mph. Had it 3 weeks and have done 200 mile. It’s like a bloody magic carpet. Best thing I’ve brought in years
Hi Alan,
Thanks for sharing. Electric bikes are great – I converted a bike for a chap in his late 80’s a while back. The look on his face when he pedalled it up the 10% hill at the top of my driveway was a picture! He contacted me recently and he’s been out on it nearly everyday since.
All the best,
Tony
Well balanced review. Recently purchased a Crossfuse, current deal sees £300 off rrp plus £150 seasonal discount and a further £160 off for British cycling membership purchased for £15. This bike at a price point of £1300 is sensational value. Had the bike for just over a week and it lives up to your positive review.
Thanks for sharing. That’s amazing value. For anyone reading this, here is the link to British Cycling – well worth joining!
All the best,
Tony
Can you tell me where you found this bike with the discounts please? Many thanks. Lyn
Hi Lyn,
The current Halfords price of £1699 is the best price I can find. It’s £200 off the regular price of £1899. If you become a member of British Cycling you will get a further 10% discount (bringing the price down to £1529). Here is a link to British Cycling, membership starts at £25 per year.
All the best,
Tony
You did well to get 10 per cent off with the british cycling membership the voucher says that it can not be used against the purchase of e bikes
Really? why? I thought it was a 10% discount on any purchase? How does one get the voucher from BC. ? do you need to apply for one?
I noticed that exclusion as well but have just bought one and the discount code appears to work
Hi Tony,
Have been reading through your site,great info thanks
Could you let me know which trusted supplier you use for the Tongsheng mid unit and suitable
battery and if any import duty is charged
Also if you have found a best motor power, battery combination for the above
More interested in reasonable power, reliability and battery life than speed
Many thanks,
John.
Hi John,
Glad you like the website, thank you for your positive comments.
I usually order from PSWPower you can order direct or via Amazon UK – the 250w version is the best option, as it is road legal in the UK. You will not need to pay any customs charges and delivery is usually with 4-5 days (from Germany). Here is the link. You will need to order the 250w VLCD5 non-coaster brake version.
A 36v 14.5ah Dolphin case battery is available from the same supplier from Amazon. I have fitted loads of these batteries and they use high quality Samsung cells. Here is the link for the battery.
If you need any more help or advice, please let me know.
Regards,
Tony