Important safety note from Canyon: the Spectral:ON CF / CFR and Torque:ON CF models may have damage to the battery

[Arminius]

Full notice - Mandatory battery check and safety notice

Extract:
„Understanding the issue
The batteries used for our E-bikes are sourced from reputable companies and tested to meet or exceed industry standards. We have been notified that a small number of batteries may be liable to damage the housing appearing as small cracks, gaps or similar.

In rare circumstances, this could allow moisture inside the battery, potentially triggering a short-circuit that bypasses the fail-safe protection mechanisms. Whilst extremely unlikely, we cannot rule out that a damaged battery might catch on fire, resulting in a risk of personal injury or damage to property.

We must instruct you to please stop using any of the affected batteries in your bike and to not charge them.
….“

 

[Pars]

Don't forgot to include the 'Do not use at all and wait for at least 4 weeks for an update' bit.
I am off work for a week purely to get some good rides in, I have 4 rides planned starting with Brecon Beacons tomorrow, then this lands!? Devastating isn't in it, especially when on my 2nd battery as my original is one of the ones pictured, it's replacement also on the list of do not use.
Have always thought Canyon's customer service has been really good so I hope this resolved in a more timely manner than what is currently being indicated. Fuming isn't in it.

 

[Winford]

Hoping they are quicker than 4 weeks, im effected, and 4 buddies with a CF8s and a CFR. My bike has been shutting off randomly since I bought it. Shimano replaced the wiring harness once, and they replaced the EP801 motor. Its probably been the battery the whole time. After they replace something it works great for a few days, thern back to shuttig down on rides. Other then that, the bike is awesome. I keep getting trophies on strava in the endurance capitol of the world.

 

[Zed.]

like many owners I've had the email, hopefully it'll be resolved soon

Rich,

 

[Arminius]

Thats what it may look like, copied from Torque:ON-Spectral:ON my22/23 Gerissne Akkugehäuse

 

[Uncomfortably_Numb]

This is what they're talking about :

There's plenty of discussion about it on the FB groups such as :

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For discussion, this was my reply to one of the threads which is relevant :-

"To be fair, and only addressing part of your thread, Shimano motors are decent, especially with the new firmware. These batteries are made under licence from Shimano under the STEPS program so the blame can't be entirely laid at Shimano's feet - especially if these batteries passed initial testing and due-diligence. Problems subsequently occuring is clearly unexpected for them but indicates a lack of product testing, clearly.

I'd be more than happy to have a Shimano powered e-bike again without hesitation however - but with a proprietory Shimano battery, not one built under licence unless it was tried and tested over a number of years, demonstrably so.
For me, the real question is what they're going to do about it, or rather, what they can do about it.

These batteries are manufactured by Trendpower (formerly Simplo) who are a HUGE battery manufacturer and they are made in batches based upon a minimum order from Canyon (I know all this after a 2 hour phone call in August with the head of Canyon Sales UK) of (I forget whether it was 100 or 200 units) basically it is a container load but the max number is quite limited due to shipping safety constraints.
There are tens of thousands of Spectral:ON's out there across the globe with these batteries so what can they possibly do about it without incurring crippling and possibly bankrupting costs.
Based upon what I know from inside industry information, the 900Wh batteries cost Canyon UK around £200 - £300 by the time they land in their London warehouse and obviously a portion of that is shipping and handling costs but even so, let's say they cost Canyon £200 each (retailing at £1100), and let's say they've sold 10,000 bikes, that's a ball park figure of £2million to replace, plus shipping to each customer which in the UK is around £60-£90 due to the Lithium battery shipping issues (a lot of couriers won't touch them now, the larger ones over a certain weight)."

 

[Uncomfortably_Numb]

And another :

 

[Uncomfortably_Numb]

The guy who owns this battery has tried epoxy resin fixes with temporary success :

 

[alleeex]

The guy who owns this battery has tried epoxy resin fixes with temporary success :

View attachment 149715

A much braver person than me…

 

[Paul L.]

I also have a battery and I would think that 4 weeks is a VERY optimistic estimate if the solution is a new battery given sourcing leadtimes and 2 weeks of boat shipment from Asia. I assume that Trendpower will be footing the bill as it is likely due to there process control. It looks like most failures are at the screw boss and I would guess it is due to issues with control of a ultrasonic insertion process.

 

[Mad_Angler1]

Looks like typical stress fatigue, they are going to need to resign the housing to resolve that and that's more than 4 weeks.

It's possible it's a materials batch issue but it's unlielly tbh.

As it's a fixing point it's carrying the load and failed.

That epoxy job is pretty rough lol.

 

[Winford]

I would guess it is due to issues with control of a ultrasonic insertion process.

Nope. Weak plastic, the cases are cracking in all different areas. What you noticed is just a weak spot. Cracking has been going on for a long time, and can be found on all areas of the case. The german forums have a thread going back to early spring on this problem

 

[Uncomfortably_Numb]

I also have a battery and I would think that 4 weeks is a VERY optimistic estimate if the solution is a new battery given sourcing leadtimes and 2 weeks of boat shipment from Asia. I assume that Trendpower will be footing the bill as it is likely due to there process control. It looks like most failures are at the screw boss and I would guess it is due to issues with control of a ultrasonic insertion process.

I think they're saying that they will have a response within 4 weeks, not a solution.

 

[whitymon]

This is just bad design in the first place, so as it reach also now some potential health issue they have no choice to stop even before having any solutions.

Could be a simple battery replacement but that would require total new design/batch (could be already in the process of it as nothing is new here), this could take long.

I do not see any other alternative honestly, one would be a new frame and new kind of battery but who knows if the new version would use shimano motor too? This would in any case be way too expensive for them.

 

[Gspot]

Maybe stress fractures from heat expansion?

 

[Uncomfortably_Numb]

Maybe stress fractures from heat expansion?

Quite possibly but as a contributing factor. These 900wH batteries weigh a LOT and those captive threads are at the bottom of the downtube so with the constant hammering, drops, jumps etc, most of the stress is at those points so it's no wonder they give.
Bad design.

 

[Dcl74]

I'm in the same boat. However having only owned the bike (ONCF9) since July24, my battery casing is in perfect condition. So I'm tempted to still ride!
Anyone else have the same thoughts!?

 

[Paul L.]

I'm tempted to still ride!
Anyone else have the same thoughts!?

If my CF8 battery has no cracks, I will be riding. Unfortunately my bike is in the shop so I can not inspect.

A properly designed and manufactured plastic housing can be extremely strong and durable. Process controls are critical to assure the strength is not compromised. Processes such as drying the resin, temperature and pressure are critical to assure the plastic maintains designed strength. Flow lines during molding cause weak areas. Improper boss insertion could cause excess stress. During ultrasonic insertion the plastic is melted during insertion. If the plastic is not melted, the result is a boss crammed in and thus plastic is stressed. Different chemicals can also greatly weaken plastic.

Whatever the cause, replacement parts are some time out. I am glad I recently ordered a Rail 9.8 XT to have a "spare" bike.

 

[Winford]

Maybe stress fractures from heat expansion?

Nope. Just brittle plastic that was to thin. Its all about saving production cost. Better plastic and a hair thicker will solve our issues. Design is not wrong. Material and craftsmanship is the problem.

 

[Winford]

Anyone else have the same thoughts!?

100% on a side note, my spectral has had nothing but problems since I bought it, due to the battery. They replaced motor and wiring, and it still shuts off. I know the battery is overheating, because sometimes it takes 5 to 10 minutes for it to cool down before the bike will power back on. So just use some caution.

 

[Uncomfortably_Numb]

Nope. Just brittle plastic that was to thin. Its all about saving production cost. Better plastic and a hair thicker will solve our issues. Design is not wrong. Material and craftsmanship is the problem.

Specification of the plastic housing - material, shape, thickness etc - all part of the design process. Bad design whichever you spin it.