I have one of the first production models of the 1613EVS and have had two problems with it in the last several years of light duty use.DISCLAIMER
I am a recreational woodworker, not a repair technician. The following experience is being shared in good faith to help others resolve problems with the router. All risk and liability associated with following this advise remains with the reader not the author.Won't Start or Starts and Then Stops Immediately
On this early model, the ON/OFF switch in the handle has a two piece case construction. It appears to be glued, with no way to open it to expose the electrical contacts inside. I noticed, however, that tapping the switch and blowing into the microscopic gaps produced a very small stream of super fine dust to exit the interior of the switch. After 15-20 minutes of constant fussing (mostly tapping while simultaneously depressing and releasing the switch) the power came on when the router was plugged back in and the switch was pressed normally. Bosch appears to have redesigned this switch on newer production models. The latest part doesn't appear to have any gaps for dust to enter, so a replacement switch may be in order when you grow weary of cleaning the old one after every few hours of operation.Depth Adjustment Changes While Running
This is scary and potentially dangerous!
This problem is most pronounced on my unit when the router is close to the maximum plunged position and mounted in a table. Others have experienced the same problem while using the unit hand held. In both operations, this is probably the most frequently used depth range because, as most of us know, you can never quite get enough bit sticking out from that base. During hand held operation, others stated that the router continued to plunge down while in use. In my case, the router was tight and did not move after locked when pushed in the direction that exposes more bit (plunged more). But mounted upside down in the table, the weight of the unit would occasionally pull the bit continuously down through the base during use, shrinking the amount of bit protruding onto the tabletop. About the only time that this MAY not be a problem is when a straight bit is being used for trimming. For all operations, especially when using a profile bit, the consequences are ruinous. And if you are foolish enough to have inserted a bit from the outside of the base that has a diameter LARGER than will fit through the hole in the base, you are asking for a serious injury! When the unit sinks low enough, it will pull the bit into the base and create instant shrapnel. On two occasions, without warning, the unit violently dropped to its maximum extended position, pulling the bit down through the hole in a fraction of a second. All of the blood drained out of my face in the blink of an eye.
Good news! The fix was easy on my unit. The problem was that the skinny top of the locking lever was bumping into the motor housing before the unit was fully locked in place.
I must confess that I thought about rotating the locking lever without totally removing it only AFTER I disassembled everything. I don't know if it is actually possible to rotate the lever without tearing everything apart or the spring becoming dislodged from the lever, but it's worth a try. If you can't rotate the locking lever without the spring coming undone, or you just want to see how the thing is put together, then continue reading.
Notice that the locking mechanism is nothing more than a brass (or brass color) tube threaded on the inside with a nut welded onto the end that fits into the plastic locking lever.
It is possible that the manufacturer located the locking lever close to the body originally to prevent the user from over-tightening the mechanism. Keep this possibility in mind now that you have extra room between the lever and motor body. You may want to use only enough pressure to firmly hold the router in place. I'm guessing that excessive pressure may not be good for the unit over its life.
To quote Norm, "Remember, there is no more important safety rule than to wear these safety glasses"