Can't sync courses from Iphone APP to Edge 540

Have you sent the course to the Edge? You click the send to device button in the app and then select which device to send to. After that you get a popup saying something like "Ready to Roll" and that it will be available after sync.

Can you post a video/screen recording here of how you are creating the course and it not sending to your Edge?

for sure -- after ready to roll there is nothing (even after multiple reboots and etc)

(Everything on iPhone)

Create course on Komoot - Download GPX file - Save directly to Garmin Connect - Course Setup (Road Cycling) - Save - Send to Device Edge 540 - Ready to Roll = NOTHING (Now I can't even find new courses via Search on Edge) 

Have you tried sending it from Garmin Connect Web? Click send to device. Then don't use Garmin Express. Just open Garmin Connect and let it sync.