How do they do that?

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
My Synergie Mistral has been on and off the road with a mysterious illness which has resulted in Synergie supplying a new motor under warranty.

But that is all they did supply, so according to ETS Cambridge, the old motor will have to be taken out of its wheel and a new motor laced into it. My son raised the question "How do they build wheels when bikes are made. Are they all put together by hand or has someone invented a machine to build a wheel?

Frankly I don't know. Could anyone enlighten us please?

Rod
 

Vikki

Esteemed Pedelecer
Jan 12, 2009
442
2
I had to rebuild my front wheel on my old PowaByke. The rim had weakened and split from the rest of the wheel causing a major blowout (a rip in the innertube half way round it :eek:

I thought I was faced with buying a new wheel at £250. But then I thought, hey! I've got a spare wheel at home. I unlaced the spare and the wheel with the motor in it and then watched a 3 part video on you tube on how to lace a wheel. However, my spoke arrangement was not the same as a 36 spoke over-over-under. So, take a photograph of how yours goes together and learn from the videos. I found it quite easy working methodically and with patience (it's a long job for a first try).

Best regards.

Vikki.
 

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
Building wheels

Thanks for the info Vickki. I should have explained that I don't have to rebuild the wheel myself. The Electric Transport Shop at Cambridge are doing that for me under the bike's warranty. However it is something I would like to know more about so I will follow your advice.

Rod
 

flecc

Member
Oct 25, 2006
53,561
30,849
"How do they build wheels when bikes are made. Are they all put together by hand or has someone invented a machine to build a wheel?

Rod

Small production plants still hand build wheels, but larger ones lace the spokes into place by hand and then the laced wheel is placed on an automatic building jig that tensions the spokes and trues the wheel.

Even hand builders often divide the duties, one person lacing and one person tensioning and truing. One husband and wife wheel production team in England use the wife with her nimble fingers lacing, the husband tensioning and truing, and they can knock out quite large numbers each day.
.
 

Vikki

Esteemed Pedelecer
Jan 12, 2009
442
2
Here's photo of what happened to my wheel.

Before anyone says "Hey! That's not a powaByke Euro", you're quite right - but it's heart is :) That'll be a story for another day but it took work.

Best regards.

Vikki.
 

Attachments

dazzie

Pedelecer
Jul 16, 2008
129
0
Hi Rob,

I own a Mistral too and it's a bit disturbing that they only provided a replacement motor, leaving you to get it fitted. I wouldn't have a clue how to replace mine and frankly I would have probably got a bit irate with Synergie and insisted on a whole wheel (with me sending the old one back after). :mad: :eek:

Daz
 

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
Synergie motor

Hi Daz

The position is that the bike went in for four weeks before Christmas making this curious buzzing vibrating noise from time to time that others have referred to here. Synergie were sent the wheel and motor and after testing it pronounced nothing wrong with it.

They sent a new control unit back to Electric Transport Shop Cambridge who proceeded to fit it and hand the bike back to me.

It made no difference at all and the fault got worse, five instances in five miles on one occasion. I took the bike back and after discussions with Synergie it was agreed the motor would be replaced. It was ETS Cambridge who found themselves with the new motor only and who then rang me to bring me up to date. As we speak I understand their professional wheel builder is doing the business on the wheel and hopefully I should get the bike back early next week.

I would not like to give the impression that ETS left it to me to fit the motor. I just hope that the fault has been cured this time. I have had the bike five months but have not had the use of it for about six weeks in that time. Being under warranty is one thing but getting things done in a reasonable time is another.

All the best

Rod
 

flecc

Member
Oct 25, 2006
53,561
30,849
As we speak I understand their professional wheel builder is doing the business on the wheel and hopefully I should get the bike back early next week.

I have had the bike five months but have not had the use of it for about six weeks in that time.
When a bike is as new as that and little used, another approach is to just swap the entire motor core into the existing hub shell and wheel, since the toothed gear ring in the hub shell has hardly any wear and will mesh with the new inner ok.

I've frequently done the same with hub gears where only the pawl engagement track is in the shell, all the real works contained in the inner core.
.
 

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
Good suggestion

I completely agree with you Flecc, but somehow commonsense and good practise don't seem to be too obvious throughout this entire saga. Rebuilding an entire wheel just to get a new motor into it seems excessive to me.

Why not simply send a new wheel and motor complete? Or adopt your idea of shifting the core.

Rod
 

Alex728

Esteemed Pedelecer
Dec 16, 2008
1,109
-1
Ipswich
incidentally when I spoke to ETS Cambridge in December about getting an lower cost e-bike I was also considering the Mistral..

However a lad there said that the Powacycle Salisbury was more reliable - and when I asked him about after sales service, he said that ETS has had better response from Powacycle with regard to obtaining spares/service etc and quicker delivery of these spares (perhaps understandable given that Powacycle are down the road in Essex)

Considering the lad turned down the chance to "upsell" to what was (at least at ETS prices) a more expensive cycle presumably with a higher profit margin I do think thats significant...

I agree either the motor core should have been replaced or a new wheel sent, no questions asked...
 

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
Hi Alex

I went for the Mistral because apart from the more expensive Wisper it was a 36 volt system. Apart from this problem, which has taken more than its fair share of time to sort out (if indeed it is now sorted out!) I really like the bike and I have had no other troubles.

It offers a range of modes including throttle, something which I consider essential, it is comfortable and very smooth to ride. I also find the gearing suits me well and fits in with the sort of terrain in which I usually ride the bike - rolling hills but nothing deperately steep.

And in spite of what people say I like the front suspension. This and the sprung seat pillar I fitted myself, make it a smooth machine.

It also comes with a rear parcel rack on which I can mount a couple of pannier bags and the range is good. Unfortunately there does not seem to be much of a sense of urgency on the part of Synergie when it comes to either diagnosing a problem or getting the spares sent asap.

Fingers crossed!

Rod
 

Alex728

Esteemed Pedelecer
Dec 16, 2008
1,109
-1
Ipswich
it was a close call for me TBH but I made my decision after checking a lot of posts on this forum and speaking to ETS

I too would have liked a Wisper but can't justify the expense yet

With all e-bikes (I don't want to single out any manufacturer) it seems that there are low stock levels, small but annoying customer service slippages (missed delivery dates, minor manufacturing errors) and early adopters have been are used as unpaid testers - at this time I personally don't have the time, cash or workshop resources to debug a premium priced (to me) product at my expense (although I appreciate the good work of people who are doing this!)

That said in 1-2 years time maybe I will be after something like a Wisper which is a good bike now and I hope will be near perfect (including access to local customer service) in a couple of years time - and I hope other companies similarly improve..

. Unfortunately there does not seem to be much of a sense of urgency on the part of Synergie when it comes to either diagnosing a problem or getting the spares sent asap.

Fingers crossed!

Rod
hope it all goes well for you but it seems a shame that the importers would let customers down like this - IMO they should have sent a new built wheel as soon as they had decided the controller wasn't duff, or better still provided spares of both... (this also indicates to me a shortage of stock/spares and/or passing the buck..)

Sorry if these judgements sounds harsh but I once worked for a British electronics company which didn't treat its customers like it should have done - it resulted in an eventual decline in revenue, staff morale and a load of layoffs and I'd hate to see these British e-bike companies and dealers (which seem to be thriving in a recession!) going the same way..
 
Last edited:

Alex728

Esteemed Pedelecer
Dec 16, 2008
1,109
-1
Ipswich
We might as well pick the ball up and go home then!!
Or ask for sponsorship of it, the pitch and your kit :rolleyes:

Didn't Mr Ching send flecc a battery to test, after the problems with Ezee batteries? Small gestures like that go a long way to restoring confidence and are good PR....

Maybe its an age thing - being younger and having grown up in London/SE England with a faster pace of life people my age expect things to be done quicker especially when they have handed over hard cash (I find Suffolks pace of life/business a bit slow sometimes)..

IMO customer service is now the final hurdle the ebike industry needs to cross - especially as sales appear to be booming - if its possible to match the service levels of conventional cycling ; that is most spares in stock, and average 2 days turnaround for repairs I'd be happy with that... (and TBH some companies seem to be getting there)
 
Last edited:

flecc

Member
Oct 25, 2006
53,561
30,849
That said in 1-2 years time maybe I will be after something like a XXXXXX which - - - I hope will be near perfect (including access to local customer service) in a couple of years time -
Unfortunately I was reading the same things two years ago.

The problem remains the same, too small a market to sustain what is needed, and the small market split among numerous suppliers.

We get the service we need with ordinary bikes and with cars because around two million of each are sold in the UK each year, the volume and user density making good service possible.

With only fifteen thousand e-bikes sold each year even now, many makes and models scattered very thinly across the UK, it's logistically impossible to reliably match the service given for normal bikes and cars. Some companies really do try their best, but the problems of maintaining consistency of good service in all circumstances are insurmountable.

The little matter of margins should also be taken into consideration. It's one matter to sell something like the Mistral at £1300 or more and give good service, but quite another to do the same at the selling price of £599 it was until recently, now £799 due to the exchange rate changes. Even at £799, there's no margin for the full spares stocks and dedicated service staff that the companies selling at nearer £1500 can often furnish.

I too would have liked a Wisper but can't justify the expense yet
It was at this point that you opted for a lesser service. I know it's a tough pill that customers never want to swallow, but we often really do get what we pay for.
.
 
Last edited:

Alex728

Esteemed Pedelecer
Dec 16, 2008
1,109
-1
Ipswich
Unfortunately I was reading the same things two years ago.

The problem remains the same, too small a market to sustain what is needed, and the small market split among numerous suppliers.
the trade press claims that e-bike sales are rising...I've been monitoring the old posts as well and I do think some companies definitely do have a policy of continuous improvement - for instance the Wisper 905SE had clearly had a lot of improvements made due to Wisper monitoring issues raised on this forum - I would hope its still kept in production in 2 years time rather than abandoned for the "latest and greatest developments"!

The other issue I found was that many e-bikes seemed to be constantly out of stock with no retailers giving accurate info about stock levels - I hope this will improve too.

it's logistically impossible to reliably match the service given for normal bikes and cars. Some companies really do try their best, but the problems of maintaining consistency of good service in all circumstances are insurmountable.
This would explain why ETS has better service from Powacycle - spares (if in stock) need only make a relatively short journey down the M11. At least ETS also mentions it will work with local bike shops and isn't that far away - its also downhill from my house to the train station... :rolleyes:

The little matter of margins should also be taken into consideration. It's one matter to sell something like the Mistral at £1300 or more and give good service,
but competing at that price level surely a Wisper or Ezee would win as they have far better bike components and performance..

It was at this point that you opted for a lesser service. I know it's a tough pill that customers never want to swallow, but we often really do get what we pay for.
.
I accept thats why I got a lower powered motor on the Salisbury compared to other models in the same price range - but the Powacycle does the job for the price -and I've heard (albeit historical now) good stories about service / support from them... Shame their new engineer doesn't contribute posts like Carl Percival used to, although they do still have their support department, i spoke to the new chap and he was helpful enough...

I expect though these companies have to be lean and maybe they don't want to have to deal with the extra marketing/PR issues brought up by a forum presence..

do you think the situation will improve with time? I can see its a tough market, as in the space of just two years many e-bike dealers have actually gone out of business... but it would be a shame to see ebikes in Britain go the way of the Sinclair C5 which the journalist guy mentioned (which I gather was a failure as much due to reliability issues as its strangeness...),

I wonder if the demand for ebikes has already gone past its critical mass to sustain the market despite these issues and the coming recession?
 
Last edited:

flecc

Member
Oct 25, 2006
53,561
30,849
the trade press claims that e-bike sales are rising...
15,000 is what they've risen to in this last year, so it's still peanuts for a 60 million population.

I've been monitoring the old posts as well and I do think some companies definitely do have a policy of continuous improvement - for instance the Wisper 905SE had clearly had a lot of improvements made due to Wisper monitoring issues raised on this forum - I would hope its still kept in production in 2 years time rather than abandoned for the "latest and greatest developments"!
But it's the extra price that pays for the development. The intention is for the 905 series to continue

The other issue I found was that many e-bikes seemed to be constantly out of stock with no retailers giving accurate info about stock levels - I hope this will improve too.
Again this is a size problem. Derby Cycles with Kalkhoff for example is a very big boy in Europe and they've struggled their way to 100,000 a year production. But e-bikes are very small part of that, split across different brands, each in several models and each model in 4 or 5 sizes, with distribution to several countries. You can see that for one particular model in one particular size in one particular country, there's a very high risk that the only one or two they got in the last batch have already been sold and with some while before a new batch will be received.

Size can also be a problem with Chinese supplies, and added to that is the three months from China to the UK for bikes ordered to arrive to supply the next three or four months need. It needs a very good crystal ball to know exactly what you or anyone else might want to buy in seven months time. If sales were a million a year it wouldn't be a problem. The profit margins just don't permit the borrowings to sustain high stock levels, and lithium batteries deteriorate with age anyway so stocks have to be as fresh as possible.

but competing at that price level surely a Wisper or Ezee would win as they have far better bike components and performance..
The difference in components doesn't anywhere near account for the difference in price. A hundred pounds or so would match the Mistral or Salisbury to a £1300 plus bike. It's the law of diminishing returns. Look at the price difference between the Mondeo V6 and the Jaguar X type that Ford created. The latter is the same car, same engine, tarted up a bit, but it costs dear, the benefits being the image and the service from the Jaguar dealer.

I accept thats why I got a lower powered motor on the Salisbury compared to other models in the same price range - but the Powacycle does the job for the price -and I've heard (albeit historical now) good stories about service / support from them... Shame their new engineer doesn't contribute posts like Carl Percival used to, although they do still have their support department, i spoke to the new chap and he was helpful enough...
I'm glad they seem to have improved, they really did need to. Following the short period of Carl's good efforts they were a disaster, bitter threads in this forum with owners waiting many weeks for spares, and in a couple of cases a compete inability to find the cause of faults on bikes. They didn't appear to have a support department at all at that time, some dealers tearing their hair out in frustration.

do you think the situation will improve with time? I can see its a tough market, as in the space of just two years many e-bike dealers have actually gone out of business...
Sadly no, and I think we'll see more supplier failures. As you see from my replies, we need more sales volume, not a growth in the 15,000 but a multiple of the present level before it can improve appreciably and match other industries. Service will stay roughly as it is, most companies trying by various degrees to give a good service but with patchy results, some customers lucky with excellent service but others far from fortunate due to the intrinsic problems I've described.
.
 
Last edited:

Rod Tibbs

Pedelecer
Jun 10, 2008
123
0
I can understand the argument that whilst e bikes sell in relatively small numbers we are not going to get perfect after sales service.

However my experience could have been totally different without it costing either the manufacturer or the dealer a penny.

Put simply, my bike has been off the road for six weeks now although spares were and are available. All we are looking at is a dreadful slowness in dealing with anything, failure to communicate, failure to tell the customer what is going on and stupid excuses like "the engineer who dealt with it is now ill and we cannot contact him."

What is needed is not warehouses full of bits but simply a willingness to communicate and deal with things efficiently. In my view this does not cost a great deal but is worth a lot to the customer.

I have been very impressed by the obvious interest Wisper takes in its customers. Sure the bikes have their problems like everyone else's but at least you have the impression someone cares, someone is reading this forum and reacting to what is going on.

If one manufacturer can do it why not others?

Rod
 

flecc

Member
Oct 25, 2006
53,561
30,849
All we are looking at is a dreadful slowness in dealing with anything, failure to communicate, failure to tell the customer what is going on and stupid excuses like "the engineer who dealt with it is now ill and we cannot contact him."

I have been very impressed by the obvious interest Wisper takes in its customers.

If one manufacturer can do it why not others?

Rod
But I've just given the reasons Rod. The Mistral supplier is a bit like an overworked one man business, not enough hours in the day, not enough resources like service staff and not enough income from low bike prices to put that right. If their one service man is in bed with 'flu, there's nothing they can do except pray he'll be back in soon.

Wisper spend a bit more on components and can then up the bikes to premium price levels, and that then pays for the resources to give a premium service to match.

As I replied to Alex above, Synergie could follow the Wisper model, but it would cost. The Mistral wouldn't cost £799 any more.

I'm not saying Synergie couldn't have done better, just describing what inevitably makes a business what it is.
.
 
Last edited: