Mahle makes a big splash. The Spanish drive manufacturer and epitome of modern rear wheel hub drives will also be building a drive system with a mid-drive motor in the future. Did you see that coming? We certainly didn’t. This makes it all the more exciting to find out what kind of system it is and which target groups the company has in mind for it.
1. Mahle suddenly with a mid-drive motor? Not suddenly.
2. What kind of system is the new Mahle M40?
3. What are the technical specs of the Mahle M40 motor?
4. What electronic features does the motor offer?
5. What batteries does Mahle present for the M40?
6. Which charger is compatible with the new e-drive?
7. How did Mahle design the operating concept?
8. Is the M40 compatible with existing ebike components from Mahle?
9. Which ebikes is this novelty suitable for?
10. How successful do we think the drive will be?
11. Which ebikes will be launched featuring a Mahle M40?
1. Mahle suddenly with a mid-drive motor? Not suddenly.
Many of you have probably heard the name Mahle associated with ebikes. The Mahle Group, headquartered in Stuttgart, is one of the world’s largest automotive suppliers. Seven years ago, in 2018, it acquired Spanish drive specialist ebikemotion Technologies. Since then, all of Mahle’s activities relating to ebikes have been concentrated in Palencia, a city in the Castile and Leon region.
Ebikemotion Technologies used to manufacture rear wheel hub drives exclusively. What began with the X35 system was continued with the X20, X30 and, most recently, the XS. With the arrival of Mahle, production was expanded to include mid-drive motors. However, this was done on behalf of and under the label of Specialized. As a result, less of this reached the public eye. In fact, the hardware for the Specialized SL 1.1 motor introduced in 2020 comes from Mahle. The same applies to the Specialized SL 1.2, which was launched in 2023. Both are smaller and lighter motors. With a torque of 50 Newton metres, the Specialized SL 1.2 is in the same range as a TQ HPR50, the new TQ HPR60 or the Fazua Ride 60. It is mainly used in sporty models from Specialized, such as the Specialized Turbo Kenevo SL e-mountain bike and the Specialized Turbo Creo2 e-gravel bike.
2. What kind of system is the new Mahle M40?
Given the history and character of previous e-drives, we would have expected a system that falls more into the ‘light assist’ category. The slogan Mahle is using to market its new development shows that we were completely off the mark. ‘Powered for the wild.’ This clearly points in a entirely different direction. The manufacturer obviously wants to serve additional segments in the future that have been largely closed to it with hub drives. ‘With the M40 system, Mahle SmartBike Systems is reaffirming its claim to continue driving the development of the eBike industry in the mountain bike segment.’ says Jochen Sommer, Managing Director of Mahle SmartBike Systems.
The focus is therefore more on almost limitless power. There is plenty of torque and a peak power output that comes close to 1,000 watts. Unsurprisingly, the M40 is not exactly a lightweight. After all, as a complete system with the smallest battery, the drive weighs around five kilograms.
3. What are the technical specs of the Mahle M40 motor?
A glance at the data sheet shows that the new electric drive follows in the footsteps of competitors such as DJI with the Avinox, Bosch with the Performance Line CX and Brose with the Drive 3 Peak. Starting from the familiar rated continuous power of 250 watts, the motor reaches an enormous 850 watts at peak. This is not quite on par with the DJI Avinox, which even reaches 1,000 watts since a software update. However, Mahle outperforms both Brose and Bosch in this respect, which deliver 600 watts and 750 watts respectively.
In terms of torque, the M40 is on a par with the Avinox. Both are specified at 105 Newton metres, which is slightly above the 100 Newton metres that the Performance Line CX will offer after the announced update in summer 2025. And the Drive 3 Peak is not far behind with its torque of 95 Newton metres.
The field of these four representatives of full-power units is even closer when it comes to the level of assistance. The 400 percent of the Mahle M40 is in line with the values of its competitors. Only the Brose motor stands out slightly with its 420 percent.
Lightweight and dynamic
Mahle has obviously done a particularly good job of optimising weight. At just 2.5 kilograms, it is virtually unrivalled in this segment. Once again, it is the DJI Avinox that can keep up here with an official weight of 2.52 kilograms. Bosch and Brose follow in second and third place with 2.7 kilograms and 2.9 kilograms respectively. Overall, the M40 looks very good on paper. It remains to be seen how this will translate into actual riding performance.
Among other things, it will then become clear how well the three support levels have been tuned. Their simple designation as Level 1, Level 2 and Level 3 suggests a classification similar to Eco, Mid and High. We are more certain, however, about the rear wheel-mounted speed sensor in the form of a disc. You will find something similar on the Avinox. The disc solution enables the e-drive to be adjusted within a very short time. Mahle states that the sensor is so accurate that it can measure a change in speed over a distance of just three centimetres. If the system can process this information quickly enough, it would provide the basis for precise adjustment of the assistance.
Mahle reveals that the motor is integrated using a design that decouples it from the frame. Thanks to the Decoupling Mounting System (DMS), virtually no vibrations generated by the motor are transmitted to the frame. The aim of this and other measures is a ride that feels powerful, smooth and natural. To achieve this, an even narrower axle width for the M40 would have been desirable. We note a Q factor of 179 millimetres. This is quite a bit wider than the distance between the pedals on a regular bicycle without electric assistance. Brose, for example, solves this better with a distance of only 136 millimetres.
Mahle M40 motor at a glance
- Rated continuous power: 250 W
- Maximum power: 850 W
- Assistance up to: 25 km/h
- Maximum torque: 105 Nm
- Maximum assistance: 400 %
- Weight: 2.5 kg
4. What electronic features does the motor offer?
One advantage of riding an ebike over a regular bike is the special features that can be used with an electric motor. The new Mahle M40 will have two such features when it is launched. The first is called ‘Hill Brake’. It kicks in when you ride up a steep hill and come to a stop, whether intentionally or unintentionally. Experience has shown that the incline makes it difficult to start again. This is especially true if you face additional technical challenges in the first few metres. Hill Brake prevents you from rolling back when you start. From an ‘Auto Hold’, you can continue your journey uphill in a controlled manner.
Feature number two is called ‘Motor Dynamic Overrun’. This refers to the motor’s coasting effect, which many of you are probably familiar with. Earlier ebike motors only reacted with a certain delay when you stopped pedalling. They continued to provide assistance for a few moments. Today, manufacturers such as Mahle use this to their advantage. They allow the motor to brake less strongly, giving you a little boost even though you are already coasting. If you use this gentle coasting skilfully while riding, you will find it easier to overcome many obstacles.
You may be familiar with functions such as Hill Brake and Motor Dynamic Overrun from other e-drives. In the current Bosch Performance Line CX, for example, they are called Hill Start Assist and Extended Boost.
5. What batteries does Mahle present for the M40?
Mahle is starting with two intube batteries integrated into the frame for the M40. According to the manufacturer, they are developed and manufactured in Europe. Both have the same characteristic angular shape. In theory, this means they can be used and exchanged as desired. In practice, however, an adapter is required as they differ in length. We do not know if and when Mahle will offer such an adapter.
The different lengths are, of course, due to the different capacities of the two batteries. The larger and heavier of the two, the Mahle Mahle iM8, delivers 800 watt hours. The smaller Mahle iM5 delivers 534 watt hours. Ebike manufacturers can therefore freely decide which battery with which capacity is best suited to their ebikes. Or they can use the battery size to differentiate between models within a series.
What about a range extender? Upon request, Mahle confirmed that the mid-drive platform will be equipped with a separate additional battery. The Mahle eX1 range extender, which is suitable for the X20, X30 and XS, is not compatible. Due to the different operating voltages of the ebike systems – 48 volts for the new M40 and 36 volts for the previous systems in the X series – this applies to all existing batteries.
Mahle iM5 at a glance
- Operating voltage: 48 V
- Capacity: 534 watt hours
- Weight: 2.5 kg
- Compatible with range extender in the future: yes
Mahle iM8 at a glance
- Operating voltage: 48 V
- Capacity: 800 watt hours
- Weight: 3.7 kg
- Compatible with range extender in the future: yes
6. Which charger is compatible with the new e-drive?
The difference in operating voltage means that a completely new charger will be required. Images of this are not yet available. However, we know that it will be similar to the existing Mahle chargers. An LED light integrated into the housing will indicate the charging progress. Thanks to fast-charging technology, the batteries should be 80 percent charged in less than three hours.
7. How did Mahle design the operating concept?
The focus on the e-mountain bike as the primary application for the M40 is reflected in the concept for operating the ebike system. On the trails, a display integrated into the top tube proves advantageous in many situations. Firstly, it is relatively well protected should you fall off the ebike. Secondly, its central position ensures that you have a clear view of the necessary data while riding. Sometimes you have to look too far towards the bike and away from the route ahead. However, this drawback applies to any display installed in this position.
Mahle even allows ebike manufacturers to choose an alternative position. The Mahle Head Unit+, as the display for the M40 is called, can also be integrated into the stem or into mounts developed specifically by bike brands for the handlebars. With its 1.9-inch colour display, it meets current standards. From the images available, it can be deduced that the information about the ride and the status of the ebike system is spread across several screens. You can obviously set how many data fields a screen contains and which data fields these should be, either directly on the system or via the app.
You can probably scroll through the screens using the Mahle Trio Remote, among other things. The wireless control unit features three buttons. In the centre, a small button with a smooth surface protrudes slightly upwards to make it easier to reach. Below and above it, you will see the other two buttons with a ribbed profile, which function like arrow keys or plus and minus buttons. The design is clearly based on that of the Duo Remote. According to Mahle, ebike manufacturers can add a second Trio Remote to the ebike system on the handlebars. In this case, the additional control unit could control additional functions via short cuts.
8. Is the M40 compatible with existing ebike components from Mahle?
As mentioned above, ‘old’ batteries and chargers cannot be used with the new system due to the different operating voltage. However, there is good news for some of the accessories. For example, the following three components can be used with the Mahle M40:
- Mahle Duo control unit
- Mahle eShifter control unit for drop bars
- Mahle Pulsar One bike computer
9. Which ebikes is this novelty suitable for?
An e-drive with a mid-drive motor and these technical specifications already answers some questions about its preferred area of application by itself. Mahle clearly sets the direction in words and pictures: The aim is to enter the market for e-mountain bikes that require the most powerful drive possible. With the data sheet and the good reputation that the manufacturer has earned within the industry, there are at least two factors that suggest that this could succeed.
Mahle itself also mentions trekking ebikes as a target market. Whether this requires such immense power remains to be seen. The same applies to whether the target group is actually asking for it. However, this could indicate the direction in which Mahle intends to develop its range of drive systems with an M in front of them in the future. The manufacturer has already announced that further mid-drive motors will be added to the M40 in the coming years.
10. How successful do we think the drive will be?
Of course, it is easy to speculate whether Mahle’s plans will work out or not. In our view, there are three main factors that speak in favour of this. Firstly, Mahle is not entering the world of ebike drives in general, nor specifically that of mid-drive motorsas a typicaly newbie. Quite the contrary. Thanks to its partnership with Specialized and the production of motors for the Specialized SL 1.1 and Specialized SL 1.2, the manufacturer has a wealth of experience at the highest level. Secondly, the name is likely to inspire confidence among potential interested parties. After all, they are well aware of the good work Mahle has been doing for years, both for Specialized and with its own drives. Thirdly, the company has a well-established international sales and service structure, which is essential for such a project.
At the same time, a few obstacles stand in the way of achieving the desired goal. The biggest hurdle is the massive, prominent and high-quality competition in the full-power drive segment. Rising star DJI. Industry leader Bosch. Established giants such as Shimano, Brose, soon to be under the umbrella of Yamaha and Giant. Motor-gear units such as those from Pinion. And. And. And. It will be extremely difficult to secure relevant market shares against this phalanx. Furthermore, at least when looking at the documentation, no feature stands out that would set the Mahle M40 really apart from the competition in the long term. Perhaps this impression will change after the first test rides. But so far, everything looks like a solid complete solution, albeit one that lacks anything fundamentally new. To remind you: In autumn 2023, Sram announced certain claims in precisely this segment with its Eagle Powertrain. Despite unanimously good reviews, the rocket has not really taken off yet.
Nevertheless, we don’t want to overstate this assessment. We simply don’t have the crucial background information. For example, how much time is Mahle giving itself to really gain a foothold in this market? Or at what price can it offer its system to ebike manufacturers? As is so often the case, time will tell how accurate our forecast was.
11. Which ebikes will be launched featuring a Mahle M40?
Without wishing to offend any of the brands in question, the list of brands launching their first ebike with the M40 at the same time as Mahle reads like a list of no-names in the bicycle industry. These are all manufacturers that we have not yet come across in connection with ebikes.
But hey, we’re not the ultimate authority in the bike business. Perhaps each brand will more than make up for its lack of name recognition with the actual quality of its models.
Abums
True to the motto ‘small but mighty,’ four passionate bikers have joined forces to launch the Abums brand – apparently as a direct result of their collaboration with Mahle. According to the company, based in San Sebastian, Spain, it is building the world’s first full-suspension e-mountain bike for enduro riding with a steel frame and integrated battery. The Abums Model One is the brand’s first and only model to date.
Labyrinth
According to Wikipedia, the small French village of Heiligenberg, about 40 kilometres from the German border, has only around 700 inhabitants. However, this did not prevent Labyrinth from settling here. It is not far from the foothills of the Vosges mountains, so the full-suspension e-mountain bike E-Agile can be tested nearby. Labyrinth previously used a Shimano EP801 in the E-Agile. Now it is switching to the Mahle drive.
Sants
Sants is also based in the Romance-speaking world. Ebikes are nothing new for the Italian manufacturer from Padua. The range already includes a city ebike with low-step frame, a hardtail e-mountain bike and a full-suspension e-mountain bike. Once again, we mainly encounter ebike systems from Shimano. The premiere of the M40 from Mahle appears to be the most sophisticated e-mountain bike that Sants has produced to date.
Titan Racing
Even under normal circumstances, ebike manufacturers from South Africa are considered exotic to us Europeans. This is all the more true when we are talking about a brand that is a cooperation partner in the launch of a completely new drive system from such a renowned manufacturer as Mahle. However, it is quite possible that Titan Racing is a real force to be reckoned with within Africa. At the very least, the manufacturer has the largest portfolio of ebikes among this quartet. It includes hardtail e-mountain bikes, city ebikes and ebikes for children. The Reaper with the Mahle M40 is Titan Racing’s first full-suspension e-mountain bike.
