e7000 broken cog / gear. Aftermarket replacements?

[kernowlogic]

I've had an e7000 motor sat in a toolbox for a couple of years after it stopped working and I had it replaced with an e8000 motor.

Yesterday, I decided to open it up and see what had gone wrong with it. Opening the unit was much easier than I expected it to be and it was immediately clear that the issue I had was the same as detailed in this thread:

Replacement parts for DU-E7000 motor

Hey guys, The DU-E7000 motor on my BMC Trailfox AMP decided to stop working - was making a grinding sound and i had no assist in any modes. Since I do not have warranty and against Shimano's better judgement I decided to open the motor. There i found a plastic cog connecting the cranks to the...

www.emtbforums.com

A couple of people in the thread linked above had managed to produce a brace for the gear / cog and I wondered whether anyone knew of any person or business selling them? I don't have access to a lathe nor the knowledge / skill to be able to produce one. It'd be great to get the e7000 up and running again as a backup. The rest of the inside of the motor looks near new - I think it covered about 300miles before it packed up but since I wasn't the original owner, and the original owner bought the bike via tri-sport-resort it didn't qualify for warranty.

 

[sputnik378]

I have an e7000 motor that did the same thing, I can't be 100% that it's the same issue, but I certainly have my suspicions. I put over 2000 miles on the motor before it failed (for reference).

I have access to a local machine shop, and I plan to crack it open and rebuild it at some point. The problem with machine shops is that one-off parts are expensive and time-consuming, so it might make it more palatable to do more than 1. I could do the work and ship you the piece if you want to split the cost.

Who knows, maybe others are in the same boat, and they'll reply here too.

I do need the exact measurements of the part to be milled and the motivation to get it done. Perhaps this is the catalyst needed to spark the process.
In regards to your e8000 replacement. Did you install it yourself, and it just worked? I have done the installation, and it's recognized/updated in the e-tube app, but it does not activate when I pedal. I plan to take it to the shop and have them plug in their Shimano diagnostics tool before I start meddling with it using aftermarket apps. I thought I'd ask about your experience as well.

 

[kernowlogic]

It seems that there are a number of people who have had the same part fail.

As for cost and splitting the cost, it'd be good to understand what this might be and then perhaps the number of people it'd take to split the cost for it to be economically viable.

For the dimensions, I'll get in touch with the 2 members on here who have managed to produce a workable brace as well as their experience with regards to longevity.

When I had the motor replaced, I had it done at a local shimano service centre (which was a fairly local bike shop). Shimano diagnosis first showed it was a faulty cable which I was skeptical about since the noise from the unit after the failure certainly sounded like a mechanical issue. After the cable was replaced there was of course no improvement and they contacted shimano for a replacement at my cost. They fitted the motor and set it up in-line with the manufacturer. I seem to remember either the manufacturer or madison had to get involved to program the unit so it had the correct mounting angle and wheel size. I think this can be done in STunlocker but I'm not 100%. As you suggest, probably best to get it done with shimano diagnostic tools, particularly if it's brand new and in warranty.

There's a guy from Poland who's very likely on this forum who specialises with repairing / refurbishing motors. He might be able to give you some insight on how he or his customers install the motors to their bikes.

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