"You want to tune your endurance test bike? That's not possible, it's forbidden!" The suggested topic for this story was quickly buried in the editorial conference. Unfortunately, I had already put my Ghost Hybride SL AMR X on a starvation diet and replaced various parts. Simply because that's what I always do with my bikes. "Oh, do I have one foot in jail now or what?" I wanted to know from my colleagues. They shrugged their shoulders. As an e-biker, am I really not allowed to change anything because an e-bike is not a normal bike in the eyes of the law, but a machine? You can find a lot of contradictory information on the internet, but expert Dirk Zedler, a sworn expert for electric bikes and qualified engineer, was able to quickly put my mind at rest: As an end customer, I am allowed to tune my e-bike however I want - with the exception of motor tuning, of course (see our interview below).
So, off with the fat! The goal of my e-bike tuning was clear: I wanted my mountain bike to weigh less than 20 kilos at the end and be better than in its standard condition. That's easier said than done, because dieting alone doesn't automatically improve an e-bike. Theoretically, the reach height increases and the handling becomes easier, but the components have to be stable, especially on an e-MTB, otherwise you will have more defects and less fun on the tour. Nevertheless, the sound barrier should fall. I weighed up the costs and benefits of the modifications. Tuning is expensive, so every change to the bike has to bring tangible benefits. The benefit is particularly high if the measure saves weight AND improves function.
From 21.4 to 19.7 kilograms - that's serious e-bike tuning
The Ghost Hybride SL AMR X S5.7+ LC was already relatively light at 21.4 kilos in size M thanks to the external battery, but had a lot of tuning potential in terms of equipment. And this was almost completely replaced in the course of the tuning marathon. Only the steel spring shock remained in the frame after a short air shock intermezzo - with the lighter shock I would have lost another 300 grams, but I couldn't top the smooth operation of the Cane Creek with it. The tuning of the Rockshox fork was very effective: I had the Yari cartridge bored out by Anyrace for very little money. Quite literally. Stefan Kecht drilled oil channels into the plastic compression unit, inserted shims where there were none before and thus optimised the friction coefficient of the bushings - for less than a hundred euros, he turned the somewhat stubborn Yari into a really smooth fork.
I can also recommend e-bikers with a Shimano motor to convert to the electronic Di2 gear system. "Ha!", some will now exclaim, others will buy a whole bike with that money! The truth is: at current road prices, the purchase is surprisingly affordable, but only available as an 11-speed drivetrain. As the rear derailleur is powered by the main battery, you only need the rear derailleur, the shifter and the interface on the handlebars. However, the motor must be authorised by the dealer, which in turn only works with written permission from the manufacturer - time-consuming and annoying, but feasible. The reward: The XT groupset can be customised to your personal taste in terms of shifting speed and direction and is absolutely reliable in its function.
Brake hack doesn't save weight - but pushes performance
Also feasible, but without any guarantee: the ultimate brake hack, which has been haunting the internet for years and goes by the name of "Shigura". Ultimately, it is the fusion of a Magura MT5 and a Shimano servo wave brake lever, for example from the SLX. I first did this five years ago and was worried whether this tinkering would cost me my health. Today I can assure you that the arrangement works and is a really great combination of high braking power and pleasant lever ergonomics. The costs are low, the weight saving is zero, but the functional gain is huge in my opinion.
Almost as big as the wheel tuning. I really wanted to fit the Eddy Current on the rear wheel. The Schwalbe monster is totally puncture-resistant and has great grip, but is extremely heavy. In combination with the lightweight Mavic wheelset and the equally slim Magic Mary with snakeskin casing, I was ultimately able to save weight AND minimise the risk of punctures. Admittedly: A rider over 80 kilos needs something more stable up front, but for me this combination of lightweight wheels and Schwalbe tyres is the perfect setup.
CONCLUSIONS: By making a total of 10 changes to the drive unit, steering centre, seat post and various small parts, I have achieved my goal: my e-bike now weighs 19.7 kilos and is better than before! Not all measures are really necessary to improve the function - the wheels and handlebars belong more in the luxury tuning category, but they also save a lot of weight. And the fun of such high-quality components is therefore a big part of the hobby for me.
Our 10 e-bike tuning measures in detail
1 - Motor operation
Costslow
Benefit: medium
The EN-EW-100 interface costs just under 70 euros and weighs 5.7 grams. It replaces the display and, thanks to the mini button, can also be used without a remote control. However, it is then difficult to change the motor function while riding and the sliding function is cancelled. A clean and easy option for people who usually only use one mode. Still clean and more functional with the E-7000 control lever (+21 grams).
2 - Handlebar-stem integration
Costs: high
Benefit: high
If it fits, the Hixon IC 1.0 a super dietary supplement! It saves several hundred grams and is still very stable. In BIKE magazine's laboratory test, it couldn't be broken. The Future look is a matter of taste. Caution: If you don't like the crank and tilt, you're out of luck. You can't adjust anything on the Hixon. And a Shimano display won't fit because it's not round. But in combination with the EN-EW 100 it works.
3 - Lightweight vario post & saddle
Costs: high
Benefit: medium
A post that works and a saddle that fits? Then you don't really need to tune anything. But you can save weight without sacrificing functionality: The Vecnum Nivo offers first-class function, is easy to service, lightweight and made in Germany! It works reliably, is adjustable in stroke and still lightweight. The SLR saddle from Selle Italia fits me like a sofa cushion and weighs almost nothing. It saves almost 300 grams compared to the standard parts.
4 - Brake hack
Costs: low
Benefit: high
Attention! This is a DIY hack with no guarantee, and if you're afraid of losing your guarantee, it's best not to read any further. But it's a cult tip on the internet, so I tried it out a few years ago. Since then, this has been my favourite hack: Magura brake caliper with Shimano servo wave lever = best brakes in the world! Great ergonomics, crisp pressure point, enormous power. And cheap to make. But only for experienced mechanics. Otherwise: better hands off!
5 - Electronic circuit
Costs: medium
Benefit: medium
Converting to Di2 is time-consuming because the motor has to be activated by the manufacturer. Nothing works without a shop or sending it in. But then: perfect shifting, customisable and always clean. You can also customise the shifting speed and direction to suit your preferences. You only need a rear derailleur and lever for an e-bike, so the conversion is affordable.
6 - Impeller tuning
Costs: high
Benefit: high
Half a kilo less rotating mass is clearly noticeable in handling and on the scales. More importantly, I wanted to install a stable, puncture-resistant rear tyre and still come in under 20 kilos. This was only possible with a very light yet stable wheelset. The Mavic XA Pro Carbon LRS has been putting up with me for a year without complaint. Of course, this costs a lot of money, but it is recommended in the combination presented here.
7 - Tuning the tyre
Costslow
Benefit: high
This is an ideal combination for me, because the Magic Mary is very light and has good grip at the front, but has never had a puncture at my weight (70 kilos). The Eddy Current at the rear is heavy but indestructible. A Schwalbe tyre combination suitable for enduro, even for Lake Garda scree. Of course, you can still save weight here, but only with massive disadvantages in hard terrain. A no-go for me!
8 - Screw-in axles save weight
Costslow
Benefitlow
Quick-release axles work: quickly. Bolted axles: not. But the Wolftooth bolt-on axle for the Yari is clean, light - and since I don't race, I have time to dig out the multi-tool when needed. The HR thru-axle from Canyon even has a hidden integrated lever and is still lighter than the original from DT. I was therefore happy to do without the 120 grams in total.
9 - Tuning the drive
Costslow
Benefit: medium
The 34 mm Wolftooth chainring has been holding the chain bombproof for months thanks to its special tooth shape. This meant that the chain guide could be omitted. Combined with a smaller, super-light cassette (Sram XG 11-95 with 10-42 teeth), a few hundred grams tumble out of the drivetrain. This gear reduction is sufficient for 90% of the climbs, even in Eco mode. When things get extremely steep, I switch to the more powerful motor mode as a lifeline.
10 - Drill out fork
Costslow
Benefit: high
The insider tip! For little money, the Tuning specialist Stefan Kecht from Anyrace upgrades the simple Yari damping cartridge (literally!), adds a customised shim stack and turns the Yari into a really good fork. This is because at high speeds, the Yari tends to develop compression pikes in standard trim, which means it hardens and loses control. Thanks to Anyrace, this is a thing of the past.
The tuning cash crash
Saving weight is expensive. 1-2 euros per gram quickly add up. But it doesn't have to be the complete tuning package.
- Wheels - 578 g - 1630 Euro - ** Function
- Steering centre - 352 g - 399 Euro - *** Function
- Attachments - 408 g - 757 Euro - *** Function
- Drive - 390 g - 665 Euro - **** Function
- Brake hack - 0 g - 60 Euro - ***** Function
- Fork tuning - 0 g - 97 Euro - ***** Function
TotalIn total, that makes a saving of 1547 grams for 3608 euros.
What is permitted for e-bike tuning?
In a short interview with Dirk Zedler, bicycle expert and expert on e-bike legislation, we clarify the most important points: What is permitted? What happens in the event of damage? And: Can I also tune the motor?
EMTB: Is parts tuning on e-bikes prohibited for end customers?
DIRK ZEDLER: No, the end customer can do whatever they want with their bike! Before the law, the e-bike in the hands of the end user is a normal bicycle. BUT: If something goes wrong, the manufacturer raises his hands. As a result, the end customer may have to pay for all conceivable damage themselves. But this is no different for a bike without a motor.
So where does the myth that you can't change anything on an e-bike come from?
According to the law, the pedelec is a machine and requires a CE mark as a complete product with all attachments, otherwise it may not be sold in Europe. As the manufacturer of an e-bike, you must prove that everything is safe before selling it. This can be checked spontaneously by the trade supervisory authority - if changes have been made, there is a risk of a sales ban. This is why manufacturers and dealers are extremely careful.
And that will change as soon as it comes into my possession?
It's about making it available on the market - this affects everyone involved in the supply chain. That is why the retailer is not allowed to change anything, because he puts the machine into circulation. That would be like forging cheques.
As a customer, can I tune everything to my heart's content?
Engine tuning for more speed is of course prohibited and punishable by law. When it comes to safety-relevant components, such as the steering centre, you should never make any compromises and should only ever install compatible handlebars and stems from the same manufacturer. This is because the most durable handlebars can break early if they are fitted with the wrong stem!
>> Unhappy with the battery performance on long, hard climbs? If you want to conquer steep mountains with your e-mountainbike in an energy-saving way, you need a smaller gear ratio: Changing the gear ratio on an E-MTB: how to convert quickly and easily
>> Read our article to find out what lighting options are available for your E-MTB - from battery-powered lamps to high beam floodlights E-bike lighting - lightshow for the trails and everyday life.
>> A simple way to make your e-mountainbike more off-road capable is to change the crank length. In the article Short e-bike cranks: tuning for off-road use we explain the conversion and its effect.
