Two things are essential for an ebike drive system. Of course, the motor. Where else would the additional support come from? We also need a battery, as the motor requires electricity. And we typically expect the battery to be built into the frame, don’t we? Mahle Smartbike is taking a different approach with its new system called XS. This drive system harks back to the days when the battery was placed on the rear rack and could be removed as a matter of course. However, Mahle is merely taking up the idea and realising it in a contemporary way. We summarise what you need to know about the new Mahle XS in a nutshell.
1. Why is the battery considered the centrepiece of the Mahle XS?
2. Which motors are part of the system?
3. Which control units and displays does Mahle offer?
4. Which other components are compatible with the drive?
5. Why does Mahle do without a permanently installed battery in the XS?
6. What configurations can we expect?
7. Which ebikes does the drive suit?
8. Can you retrofit the Mahle XS yourself?
9. When will the first ebikes with a Mahle XS appear?
1. Why is the battery considered the centrepiece of the Mahle XS?
The description of a new ebike system usually starts with the motor. The Mahle XS is definitely a somewhat more unusual drive. Much, if not everything, of its concept revolves around the battery. There is no large, even permanently integrated battery here. The system draws its energy exclusively from the external eX1 battery.
This may be familiar to some of you. Basically, it is the e185, which Mahle first presented in 2022 as a range extender for the X20 drive. Even back then, it had the distinctive shape reminiscent of a water bottle for cycling and also took up comparably little space on the frame. The e185 has been called the eX1 for some time now. Despite the name change, its key technical data has remained the same. With a weight of around 1.1 kilograms, it has a capacity of 171 watt hours. Under optimum conditions, this could be enough for a maximum range of 60 kilometres. As hardly any of us ride constantly under these optimum conditions, distances of between 40 and 50 kilometres seem much more realistic.
Not everyone is always on tour
But why would a drive manufacturer deliberately design one of its systems around such a small battery? Marco de la Serna, Head of Product, Strategy and Business Development at Mahle SmartBike Systems, answers this question with the real-life behaviour of ebike riders. ‘In our research, we found that even less than 100Wh are sufficient for most daily activities — urban commuting, short rides — so we focused on optimizing for what riders need. The result is XS: a light, efficient system that perfectly suits everyday use.’
Mahle has even paved the way for two or more eX1s to be used on one ebike at the same time. However, in view of the increased weight, the space available on an ebike and the appearance, we believe that this would tend to minimise the advantages of the Mahle XS compared to conventional systems with larger batteries.
2. Which motors are part of the system?
One of the advantages of the minimalist approach is its flexibility in the choice of motors. The Mahle XS can be combined with the manufacturer’s two latest rear hub motors, i.e. both the X20 and the X30. Both provide the familiar 250 watts in continuous operation. Basically, however, the X20 ranks ahead of the X30. Although it is around 500 grams lighter, it generates a torque of 23 Newton metres. This contrasts with the 18 Newton metres of the X30. Mahle uses an internal formula to convert these values to corresponding equivalents for mid-motors. In many places you will therefore read 55 Newton metres for the X20 and 45 Newton metres for the X30.
Which of the motors is used depends largely on the ebike into which it is to be integrated. The X20 with its thru-axle requires an installation width of 142 millimetres. Using a threaded axle, the X30 requires an installation width of exactly 136.5 millimetres. What both have in common is the option regarding the sensors. They can be used with a simpler PAS (Pedal Assist Sensor) or combined with a sensor that records torque and cadence.
3. Which control units and displays does Mahle offer?
The picture is just as flexible as when deciding on the respective motor when we look at the control units and displays. The Mahle XS can be operated via the Duo Remote, the eShifters and the control unit, which can be integrated into the top tube. You can also expand the system with a PulsarONE display from Mahle. In sum, there are plenty of options for creating a suitable operating concept for a wide range of ebikes with flat bars and drop bars.
4. Which other components are compatible with the drive?
The Smart Controller of the Mahle XS has not yet been mentioned. It ensures that the drive system can adapt its performance to the current riding situation. Are you going up a hill or hurtling down a descent? How much power are you putting into the pedals? This and other information is passed on in real time.
The drive is also compatible with the Mahle Energy Hub charging station. You can place it on your workstation, for example, where you can charge the battery and connect it to other mobile devices thanks to a USB-C port. Of course, charging the eX1 is even faster with the actual charger, the Mahle Active Charger.
5. Why does Mahle do without a permanently installed battery in the XS?
It quickly becomes clear that Mahle wants to position the new system in a niche market. Due to the low battery capacity, the XS can hardly count as a fully-fledged ebike drive. Nevertheless, there are some details that speak in its favour. It starts with its low weight. A combination of Mahle eX1 and Mahle X20, together with the other smaller components, comes to a total weight of around 2.5 kilograms. Just for comparison: the lightest mid-motor currently available in the full-power segment, the Giant SyncDrive Pro2, weighs 2.75 kilograms on its own.
The absence of a large, permanently installed battery is certainly the greatest strength of the solution. Bicycle manufacturers can accommodate it in an ebike with significantly less effort – and therefore at lower cost – than would otherwise be the case. This could be attractive wherever the integration of a larger battery in or on the frame poses a certain problem. The Mahle XS counters this with its special adaptability. At the same time, maintenance of the system is simplified.
For ebike riders, convenient charging in particular could become a selling point. Easy to remove. Just as easy to put back in. Compact dimensions. Pleasingly light. Short charging time. Can be stored in a dry, warm place for longer periods without any problems. Even with large removable batteries, this cannot always be said.
6. What configurations can we expect?
The flexibility with which bike manufacturers can handle the system has already been mentioned in the article. It is impossible to predict what they will actually do with the multitude of options. Mahle itself shows a variant in which not a single control unit is provided. You would only have access to the drive via the PulsarONE display. We’ll have to wait and see which of these will be implemented on future ebikes.
7. Which ebikes does the drive suit?
Let’s start by naming the ebike types on which you will probably never see a Mahle XS in use: e-mountainbikes, trekking ebikes, touring ebikes, SUV ebikes, e-cargo bikes. That already eliminates a lot. But there are still candidates. Simpler urban ebikes, for people who may not want or need to cycle every day. Who tend to cover shorter distances of four or five kilometres. Who are not worried about recharging the battery every day. And who don’t want to or can’t afford to spend 3,000 euros or more on an ebike.
8. Can you retrofit the Mahle XS yourself?
At first glance, the minimalist system may seem almost like a retrofit kit. However, the manufacturer makes no mention of such an option in its press release. We therefore strongly assume that it will only be supplied to bicycle manufacturers. Especially when the majority of the cables and components such as the system controller are integrated into the frame, there seems to be no alternative. However, it may be possible to add further components to the system on complete bikes at a later date. The necessary compatibility with each other is a given. The future will show what strategies bike manufacturers pursue in this respect.
9. When will the first ebikes with a Mahle XS appear?
At the moment we can’t say. In the course of the presentation, Mahle did not refer to any models that can be expected in the foreseeable future. All that is certain is that the manufacturer is making the drive available to interested parties with immediate effect.
Pictures: Mahle Smartbike Systems
