[PSA] Catastrophic Factory Defect on new Velotric Discover M - Check your brakes NOW!

Posted by ceoloide@reddit | ebikes | View on Reddit | 24 comments

TL;DR: If you have a Velotric Discover M, DO NOT RIDE IT until you have checked your front and rear rotor bolts. Look at the white witness marks: if they don't line up, your bolts are actively backing out and your brakes could fail at any moment.

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Hey everyone, I need to share a severe safety incident I just experienced with my brand-new Velotric Discover M (received less than a month ago). If you own this bike, please read this and check your wheels immediately.

I was commuting home in Manhattan traffic at around 20mph when I hit the brakes and heard a massive "clang" from the rear. I immediately lost all rear braking power, the speedometer dropped to zero, and the motor cut out. I use this bike to commute with my child, so if the loose rotor had jammed the wheel, this could have been tragic.

When I inspected the bike at home, I found the rear disc rotor and the speed sensor plate completely detached and dangling. All 6 rotor bolts were gone. The actual aluminum hub flange also had snapped. One of the bolt eyelets completely fractured off the hub under the braking stress (see photo). A simple bolt replacement won't fix this; the rear hub is structurally totaled.

[Snapped hub flange](

I then checked the front wheel to see if those bolts were secure. Take a look at the photo below. The factory-applied white "witness marks" on the front rotor bolts have significantly drifted. This proves the front bolts are actively backing out as well.

This confirms this isn't a one-off broken part, it is a systemic factory assembly failure where thread-locker and proper torque were not applied to the primary braking systems during manufacturing.

I have officially filed an incident report with the CPSC (Consumer Product Safety Commission) because this is a life-threatening defect.

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Scott7235@reddit

I recently had the same problem with my Velotric Discover M as well.

What happened: while riding I suddenly noticed that my rear brake didn’t work? Fortunately, there wasn’t any lockup of the rear wheel and the front brakes worked fine.

When I inspected the rear brakes I noticed that the rotor was totally detached from its mounting hub and all six screws were missing? I also noticed that the Speed Sensor Disc which mounts to the same hub was totally detached as well. It attaches with the same six screws as the brake rotor.

Fortunately, I was able to keep riding Without any problems except for no rear brakes. Once I continued riding, I did notice that my speedometer wasn’t working and was reading “0”?

Then, after about ten minutes of more riding my bike shut off? It turns out that the reason my bike shut off after ten minutes is because After 10 minutes of more riding my bike shutdown unexpectedly?

It turns out the reason the bike shutdown is because the controller wasn’t getting a speed signal from the speed sensor and turned off after 10 minutes. That was the setting I had set for the bike to shutdown after 10 minutes of being inactive.

I fixed this shutdown problem by changing the amount of time before shutdown to the max “ 1 hr”.

It turns out I was able to completely fix my rear brake and speed sensor by purchasing a special screw kit from Amazon for less than $10.00 with two day shipping.

My rear rotor and speed sensor weren’t damaged, and fortunately, my rear mounting hub wasn’t broken like the original poster’s.

Thanks to the original poster for communicating this important safety issue!

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ceoloide@reddit (OP)

Please consider filing a report to the CPSC (so they can follow up with the company) and write an email to Velotric, this type of failure is extremely serious and can lead to injuries or death if the rotor detaches and locks the wheel (eapecially the front one).

If this is widespread, Velotric should issue a recall or alert all buyers and pay for a mechanic to do a safety inspection.

I had to deal with Rad Power Bikes's exploding tires on a Rad Wagon 4. Luckily my rear tire exploded while the bike was parked.

Tomorrow I will unscrew one of the bolts on the front rotor to see if it has any threadlock.

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TieSpecialist3054@reddit

Did it have the thread lock?

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Chris-8521@reddit

Got the following proactive email from Velotric (meaning I had not opened a ticket):

This ticket was created on your behalf.

To add additional comments, reply to this email.

Dear Velotric Discover M Owner,

We are reaching out to inform you about a complimentary upgrade for your Velotric Discover M electric bicycle. As part of our ongoing quality review, we identified that a subset of Discover M electric bikes, built with 8mm rear hub bolts, may not provide the expected clamping force under certain extreme riding conditions. As a precautionary measure, we are replacing the original 8mm bolts with upgraded 11mm bolts.

Immediate Action Required: To ensure your continued safety, please stop riding your Velotric Discover M immediately until this complimentary hardware upgrade is complete.

What We Are Doing for You: Complimentary Replacement Kit: We have arranged for a hardware kit with six upgraded 11mm bolts to your shipping address on file. Complimentary Service Credit: We are issuing a $120 credit to the original payment method used to purchase your bicycle, which will cover the upgrades and the service. (The upgrades will take approximately 5-10 minutes) Your Next Steps: Receive Your Kit: Once the replacement kit arrives, schedule an appointment with a local bike shop. Schedule Service: Take your bike and the kit to a local bike shop. Provide the mechanic with this installation guide: [Discover M Rear Hub Bolts Replacement SOP] Reply to this Email and Send us the Invoice: After the work is completed, please reply with a copy or photo of the shop's labor invoice to confirm your bicycle has been completely upgraded. Thank you for your quick action on this matter. We're handling this upgrade to ensure things are taken care of for you.

Sincerely,

Velotric Customer Experience & Service Team

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ChoccyPeppy@reddit

I just got the same email. I came here to verify it wasn't some sort of phishing scam. Seems like it may be legit

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boncros@reddit

do they have loctite on them? I'm guessing they don't.

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ceoloide@reddit (OP)

They do have threadlock, but they were so loose I could unscrew them by hand after a small push.

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Yaakeqin@reddit

Glad you are ok

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UsernameTaken1701@reddit

What did Velotric say when you contacted them?

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unseenmover@reddit

thats been an issue for a while. When assembled they dont center the calipers over the rotors so the rotor bolts back out..

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Soltea@reddit

When assembled they dont center the calipers over the rotors so the rotor bolts back out..

What.

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Fair-Discipline-1005@reddit

Strange,Velotric is a good brand...

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Chris-8521@reddit

Just asking - have you reached out to Velotric? What was their response?

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ceoloide@reddit (OP)

They offered a full wheel assembly, rotor, and bolts repair kit, and will pay for mobile mechanic (Velofix) to come to my building and do the repair (I'm in NYC, so no car :D). I've also asked for additional bike shop service to do a full safety inspection. My main concern is that when the rotor detached it may have scored the frame, ruined the speed sensor, or other hard to gauge damange that will bite me later.

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funcentric@reddit

Thanks for taking the time to share this. Glad everyone is okay

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Laserdollarz@reddit

Inspect your ride every time. Idk how many times I've gotten my bike packed and ready for my commute, only to find a broken spoke right before I hop on.

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ceoloide@reddit (OP)

That is sound advice, but not always practical. I don't have good light where the bike is stored, and I carry kids to school so I can't inspect every bolt. I look (and pay attention to) common failure points. A brake rotor is genuinely new to me.

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dick_ddastardly@reddit

Bike maintenance and inspections are part of responsible ownership.

Glad OP wasn't hurt. Blue Loctite would be a wise investment

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ceoloide@reddit (OP)

Thank you! Luckily it was the back wheel, and it didn't lock. No child with me at that time and I could stop safely.

What you say on maintenance and inspection is true, but there are some limits to this. The disc brake assembly is not something I would check, it's the first time I hear or see bolts coming off, since it's trivially addressed at the factory. This could well be considered a manufacturing defect.

I had inspected the bike when assembling it, and the witness marks on the calipers gave me more confidence than I should have had. I also check all the other usual suspects, bolts on the handlebar, tuning the derailleur or brake calipers.

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SwvellyBents@reddit

I've got one on order now. It's my first ebike so I'm paying my local shop to assemble mine and it includes 2 years of maintenance and tune ups. So hopefully they will be cognizant of any known problems.

I have to ask so please don't take offense, did you assemble the bike? Are you absolutely certain this is a factory problem?

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ceoloide@reddit (OP)

I have assembled it (and have experience maintaining bikes), but all you need to do for this Velotric bike is install the front fork/wheel and handlebars, basically.

The bolts come with witness marks, so I assumed they were installed properly and judisciously. I did not test the torque of each bolt, or whether it came with Loctite / threadlock. It's painfully clear now I should have inspected the bike after each ride or at least once a week, but that's a major commitment in a Manhattan apartment.

In the first couple of weeks I paid close attention to sounds, but nothing stood out other than some faint clicks I was attributing to the brake calipers engaging.

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