Mahle SmartBike Systems unveils first full-power mid-drive

Micromobility Mahle SmartBike Systems Unveils First Full-Power Mid-Drive

2025-06-18 From Stefanie Eckardt | Translated by AI 3 min Reading Time

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Mahle SmartBike Systems is entering the e-mountain bike segment and expanding its portfolio with a mid-drive motor. With the full-power drive system M40, the user benefits from a lightweight design of 2.5 kg, a torque of 105 Nm, and a peak power of 850 W.

With the M40 system, Mahle SmartBike Systems has launched its first mid-drive solution, which is particularly suitable for challenging environments.(Image: Mahle) — With the M40 system, Mahle SmartBike Systems has launched its first mid-drive solution, which is particularly suitable for challenging environments.
(Image: Mahle)

The company has designed the drive primarily for electrified mountain bikes and trekking bikes. Newly developed batteries, controllers, displays, and other accessories complement the system, which is also compatible with all the contents of the company's own ecosystem. M40 is the first drive of the new M series, which will be further expanded in the coming years—in addition to the already existing X series with the hub drives X20, X30, and XS.

Drive System

The heart of the compact drive system is the new drive unit housed in an extremely lightweight magnesium casing. With a weight of 2.5 kg, a torque of 105 Nm, and a peak power of 850 W, the M40 has a power-to-weight ratio of 340 W/kg. Additionally, the drive provides an assist ratio of up to 400 percent.

The drive system is compatible with the ETOR crank standard, ensuring easy integration into a variety of cranksets available on the market. The motor is decoupled from the frame using the manufacturer's Decoupling Mounting System (DMS) to reduce the transmission of vibrations into the frame.

High Accuracy

The integrated software ensures a smooth, progressive motor response without jerky movements or abrupt power spikes through an ultra-precise speed sensor. The system collects riding data and adjusts the support dynamically and precisely. With the ability to detect speed changes over less than three centimeters of riding distance, the system offers greater accuracy than comparable market offerings.

The M40 system also includes the following ride control functions:

Motor Dynamic Overrun reduces the braking effect of the motor and allows for smooth coasting after pedaling. This enables obstacles to be overcome easily. Additionally, thanks to a highly sensitive sensor, the system independently adapts to the riding speed, ensuring a more natural riding experience tailored to riding demands.
Hill Brake prevents rolling back when stopping on steep inclines through an auto-hold feature of the motor—for controlled, safe starting.

Batteries

According to the manufacturer, the new drive impresses with optimized energy consumption, especially at high support levels. This allows for the use of smaller, lighter batteries without performance loss and offers manufacturers more design freedom for agile and easy-to-handle bicycles.

The M40 is powered by new, powerful 48V batteries from Mahle, which are developed and manufactured in Europe. These include:

Battery iM5 (534 Wh): Together with the iM5 battery, the M40 drive weighs just under 5 kg, making it one of the lightest combinations on the market.
Battery iM8 (800 Wh) allows for a range of up to 150 km autonomy or 2,500 m altitude difference.

Since both batteries are identical in shape and have the same connectors, they can be used and exchanged interchangeably. Additionally, they are fast-charging capable.

More Individuality

Mahle SmartBike Systems develops e-bike solutions that each bicycle manufacturer can customize and configure according to their brand identity and application. This also applies to the M40 system. The motor settings are defined together with the manufacturer and stored at the end of the bicycle production process. This allows each brand using the M40 system to customize bicycles individually. Additionally, the Mahle Accessory Gateway allows components from other manufacturers to be integrated into the supplier’s ecosystem.

Accessories

With the M40 system, the manufacturer introduces new accessories, such as

Head Unit+ is a compact and modern display with a 1.9-inch color screen and several mounting options. It offers clear and customizable information at a glance. The Head Unit+ is updatable and can be expanded with future features and improvements.
Trio Remote is a wireless, compact control device that is easy to use and provides intuitive access to key functions and LED status indicators, while allowing the rider to keep their hands safely on the handlebars. A second Trio unit can be added with shortcuts to control additional functions.

For the M40, already existing accessories can also be used in full compatibility, such as the Duo handlebar remote control, the eShifter assistance level control, or the ANT+ bike computer Pulsar One.

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Additionally, users can connect to MAHLE SmartBike Systems' digital ecosystem via their e-bike, laptop, smartphone, or Apple Watch and access its numerous features. (se)