June 6, 2025 - Mahle SmartBike Systems, which has been extremely successful for years with hub drives as part of lightweight, integrated and smart eBike systems, is now expanding its range to include a mid-drive for the first time, thereby entering the e-mountain bike (eMTB) segment. The new M40 full-power drive system offers full control, power and high efficiency even in demanding environments and even at high support levels and cadences.
The M40 weighs just 2.5 kilograms and generates an impressive torque of 105 Newton meters (Nm) and a peak power of 850 watts (W). This makes the M40 one of the most powerful systems on the market. Newly developed batteries, controller, display and other accessories complement the M40 drive system, which is also fully compatible with all accessories and digital tools of the established Mahle ecosystem. The M40 is the first drive system in the new M series from Mahle SmartBike Systems, which will be further expanded in the coming years to complement the existing X series with the X20, X30 and XS hub drives. The M40 drive system is available immediately.
From road pioneer to trail expert
“Thanks to state-of-the-art technologies, precision engineering and intelligent connectivity, the M40 sets new standards in the category of full-power mid-motors,” said Jochen Sommer, Managing Director of Mahle SmartBike Systems. “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.”
The M40 was developed especially for electrified mountain bikes and trekking bikes. It offers off-road e-bikers a powerful but natural riding experience with active yet controlled support that adapts to every riding situation. Thanks to its strengths, M40 is also a very well-balanced system for urban use and can therefore be used in a variety of ways.
Performance data of the motor
True to the “Light. Sport. Smart.” philosophy of MAHLE SmartBike Systems, this new drive system is also extremely compact. The centerpiece is the ultra-modern drive unit, which is housed in an ultra-light magnesium casing.
With a weight of just 2.5 kg, a torque of 105 Nm and a peak power of 850 W, the M40 has one of the best power-to-weight ratios on the market: 340 W/kg. In addition, the drive delivers a support ratio of up to 400 per cent.
In conjunction with an optimized aluminum shaft and a Q-factor of 179 mm, the motor offers exceptional versatility combined with top performance.
The drive system is compatible with the ETOR crank standard and therefore ensures simple integration into a wide range of cranksets available on the market. The motor is decoupled from the frame via the Mahle Decoupling Mounting System (DMS) in order to reduce the transmission of vibrations into the frame.
System control and behavior
The M40 system offers a powerful yet natural riding experience with strong controlled support that adapts seamlessly to every riding situation. It ensures smooth power delivery even at high cadence and enables rider-controlled performance, especially on technical trails and when climbing. Equipped with the most advanced sensors on the market, the M40 offers maximum responsiveness.
The integrated software uses an ultra-precise speed sensor to ensure a smooth, progressive motor response without jerky movements or abrupt power peaks. The system collects riding data and adjusts the assistance dynamically and precisely. With the ability to recognize changes in speed over a distance of less than three centimeters, the system offers greater accuracy than comparable offerings on the market.
The M40 system also includes advanced driving control functions:
Motor Dynamic Overrun: reduces the braking effect of the motor and enables a smooth overrun after pedaling. This makes it easy to overcome obstacles. In addition, thanks to a highly sensitive sensor, the system adapts independently to the riding speed and ensures a more natural riding experience that is customized to the riding requirements.
Hill Brake: prevents rolling back when stopping on steep inclines thanks to the engine’s “Auto Hold” function for a controlled safe start.
Batteries, range and efficiency
An outstanding feature of the M40 drive is its optimized energy consumption, particularly at high support levels. This enables the use of smaller, lighter batteries without any loss of performance and offers manufacturers more design freedom for agile and easy-to-handle bikes.
The M40 is powered by the new, powerful 48V batteries from MAHLE, which are developed and manufactured in Europe.
iM5 Battery (534 watt hours – Wh): Together with the iM5 battery, the M40 drive unit weighs close to 5 kg, making it one of the lightest combinations on the market.
iM8 Battery (800 Wh): allows a range of up to 150 km autonomy or 2,500 m altitude.
As both batteries are identical in shape and have the same connections, they can be used and exchanged as required. They are also fast-charging.
Individualisation
Mahle SmartBike Systems develops eBike solutions that every bicycle manufacturer can customize and configure to suit their brand identity and application. This also applies to the M40 system.
The motor settings are defined together with the manufacturer and saved at the end of a bike’s production process. This means that every brand that uses the M40 system can offer bikes with unique riding characteristics. Certain components from other manufacturers can also be integrated into the MAHLE ecosystem via the MAHLE Gateway.
Accessories
Mahle presents new accessories with the M40 system:
Head Unit+: is a compact and modern display with a 1.9″ color screen and multiple mounting options. It offers clear and customizable information at a glance. The Head Unit+ is updateable and can be expanded with future functionalities and improvements.
Trio Remote: is a wireless, compact control unit that is easy to use and provides intuitive access to the most important functions and LED status displays while the rider keeps their hands securely on the handlebars with the possibility of change the levels of assistance. A second Trio unit can be added with shortcuts to control additional functions.
Existing Mahle accessories such as Duo remote, eShifters or the ANT+ bike computer Pulsar One can also be used for M40 with full compatibility.
Connectivity
In addition, users can connect to the digital ecosystem of Mahle SmartBike Systems via their eBike, laptop, smartphone or Apple Watch and access its numerous functionalities.
For further information:
Website Mahle M40 is here.
Mahle SmartBike Systems website is here.
