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Problem solved!!!!! :) Turning the drive gear around got rid of the rumbling noise. I've learned a very important lesson from this: check the simple things first and don't jump to conclusions. Weird thing is the cog doesn't look worn to the naked eye, but obviously is. A really big thank you to...

Flecc that's brilliant!! Will try this later today. I am also going to have to give your website a more thorough read.

Latest update: A big thank you to Martin for his kind offer of a dead Panasonic motor so I could swap the bearings over. It arrived this morning. I've so far swapped the complete nylon cog assembly, but the rumbling is still there :-( I'm now wondering whether the rumbling could be caused by a...

Thanks flecc, off for my daily bike ride, will look into it when I get back.

This seems quite odd, crank arm nut is usually 14mm, standard on most bikes, and needs a socket to remove. Are your crank arms square taper or splined?

Tried 2 motor factors and the largest local bike shop, no joy :-( . They all seem to think the bearings are ok, but hard to tell without a load on them, and none have a puller they feel could get them off without damage. They also think that not all the bearings are standard and my best bet is...

I don't think it's an electrical problem as there is no problem with drive slipping or loss of power.

yes I'm in complete agreement there. Now to source a small bearing puller and replacement bearings. Motor factors?

No it's smooth, maybe I'm imagining the movement. I think the only way to sort this is to change all the bearings, put it back together keeping my fingers crossed. As it is the bike has little value so I've nothing to lose and maybe a fixed e-bike to gain.

I've taken out the spiral gear and the rear bearing seems ok. However on looking inside the motor it would appear that there are signs of wear. I'm assuming that the inside would normally be coated with a thin layer of black plastic, but there are 2 sections opposite each other where I can see...

Thanks for the help Flecc. The motor is now off (hammer & chisel worked a treat). The only bearing that I can feel any play in isn't the one on the motor but the small one under the nylon cog. Could this be the cause of the rumbling? Having taken it all to bits I'm thinking of replacing all of...

Thanks for the reply Flecc. The link didn't work for me. What is the normal life expectancy for one of these motors?

Hi, sorry should've mentioned that I've got as far as I have by following Flecc's excellent site.

Hi All, My wife's Raleigh Dover recently starting making a rumbling noise when the motor is in use. I've taken the motor off the bike, split the casing and checked the bearings. Can't find anything obvious, so I want to check the bearing on the motor. So far all I've managed to do is crack the...